JP2002091543A - Production plan preparing method, information processor and production managing system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To rapidly prepare a production plan. SOLUTION: At first, the required production amount of each management article kind at every ten days is heaped concerning the first priority order line of the first day (the eleventh of July) of the ten days in accordance with a article kind classification line priority order restriction. Then the violating portion of the restriction (a violation in a brand number, for example) is removed on the succeeding day (the twelfth of July). Moreover, the other restriction violating portions(beyond production ability, for example) are removed on the succeeding day (the thirteenth of July).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production plan creation method, an information processing apparatus, and a production management system.
The present invention relates to a production plan creation method for creating a production plan for producing a plurality of types of products in a plurality of factories each having a plurality of lines, an information processing apparatus, a memory medium storing a program for controlling the information processing apparatus, and a production management system. .

[0002]

2. Description of the Related Art It is necessary to prepare a product production plan for each product type, factory, day, and line (manufacturing line). Conventionally, such a production plan has been created based on the experience and intuition of the person in charge.

[0003]

A great deal of labor and time are required for creating a conventional production plan relying on experience and intuition. For example, taking a beer production plan related to the work of the applicant as an example, an enormous number of man-hours are required to create an annual production plan in factories nationwide. Beer production,
In view of the number of varieties, the number of factories, the number of lines, and the like, it can be said that it is difficult to reduce the number of steps in creating a production plan that relies on experience and intuition.

[0004] In addition, the conventional method of creating a production plan cannot create an appropriate production plan unless the plant equipment, personnel, manufacturing processes and the like are well-known, so that the human resources involved in the production plan cannot be created. It takes a very long time to grow.

Further, according to the conventional method of creating a production plan, when starting production of a new product, a considerable amount of time is required to determine whether or not all products including the new product can be produced without any trouble. And the judgment may be erroneous.

Further, according to the conventional method for creating a production plan, it is difficult to quickly and appropriately correct the production plan when a line failure or the like occurs.

[0007] The present invention has been made in view of the above background, and has as its object, for example, to speed up the creation of a production plan.

[0008]

According to a first aspect of the present invention, there is provided a production plan creating method for processing an information processing apparatus for producing a plurality of types of products in a plurality of factories each having a plurality of lines. It is characterized in that it is created by using.

This production planning method includes, for example, a step of determining a required production amount for each type of plant and for each day based on an expected total sales of each type and a preset distribution parameter; And a step of creating a daily production plan for each of the plurality of types based on the required production amount for each type of factory for each type.

In the step of preparing the daily production plan for each line, for example, the required production amount for each type of plant, for each plant,
It is preferable to include a step of allocating a plurality of lines of the relevant factory based on a preset priority.

Alternatively, the step of preparing a daily production plan for each line may include the step of setting the required production amount for each type of factory and each day for a plurality of lines of a corresponding factory by a first constraint set in advance. It is preferable to include a pile-up step of pile-up based on the above-mentioned, and a pile-breaking step of breaking down a part of the required production amount piled up in the pile-up step that violates a preset second constraint.

The crushing step is a step of crushing the constraint violation to another line of the same factory on the same day, and / or a step of crushing the constraint violation to another factory on the same day, and / or Alternatively, it is preferable that the method includes a step of breaking down the constraint violation on another day of the same factory. Here, the step of crushing the constraint violation on another day of the same factory includes the step of crushing the constraint violation by moving it backward, and / or the step of crushing the constraint violation by moving it forward. May be included.

It is preferable that the landslide step includes a step of landslide to another factory while bringing forward the constraint violation.

A production plan creating method according to a second aspect of the present invention creates a production plan for producing a plurality of types of products in a plurality of factories each having a plurality of lines by using an information processing device. It is characterized by the following.

This production planning method comprises the steps of: determining a required production amount for each type, for each plant, and for each period, based on the expected total sales for each type and a preset distribution parameter; Creating a daily production plan for each of the plurality of types based on a required production amount for each type of plant and for each period.

In the step of preparing a daily production plan for each line, the required production amount for each type of plant and for each period is determined based on a preset priority order for a plurality of lines of the relevant factory. It is preferable to include an assignment step.

Alternatively, the step of creating a daily production plan for each line is performed by dividing the required production amount for each type of plant and for each period with respect to a plurality of lines of the relevant factory on a specific day of the relevant period. A stacking step of stacking based on a preset first constraint, and a crushing step of crushing a constraint violation part of a required production amount stacked in the stacking step that violates a preset second constraint. It is preferable to include

The crushing step is a step of crushing the constraint violation to another line on the same factory on the same day, and / or a step of crushing the constraint violation to another factory on the same day, and / or Alternatively, it is preferable that the method includes a step of crushing the constraint violation in the same factory for a corresponding period, for example, by moving backward, and / or a step of crushing the constraint violation by moving forward in the previous period. .

The production plan creation methods according to the first and second aspects of the present invention are suitable, for example, for creating a beer production plan.

An information processing apparatus according to a third aspect of the present invention is an information processing apparatus for creating a production plan for producing a plurality of types of products in a plurality of factories each having a plurality of lines. Means for determining the required daily production amount for each type of plant based on the expected total sales of the type and the preset distribution parameters; and Means for creating a daily production plan for each of the plurality of types based on the line.

An information processing apparatus according to a fourth aspect of the present invention is an information processing apparatus for creating a production plan for producing a plurality of types of products in a plurality of factories each having a plurality of lines. Means for determining the required production amount for each type of plant and each period based on the expected total sales for the type and the preset distribution parameters; and Means for preparing a daily production plan for each of the plurality of types based on the plurality of types.

A memory medium according to a fifth aspect of the present invention comprises:
A program for causing an information processing apparatus to execute the production plan creation method according to the first and second aspects is stored.

A production management system according to a sixth aspect of the present invention comprises a plurality of factories each having a plurality of lines and information processing for creating a production plan for producing a plurality of types of products in the plurality of factories. Device, the information processing device, means for determining the required production amount by type, factory, day by day based on the expected total sales for each type and the preset distribution parameters, a preset constraint and Means for creating a daily production plan for each of the plurality of varieties based on the required production amount for each of the varieties and factories, wherein the plurality of factories are created by the information processing device. It is characterized by having means for referring to a production plan for each line and each day through a network.

According to a seventh aspect of the present invention, there is provided a production management system comprising: a plurality of factories each having a plurality of lines; and information processing for creating a production plan for producing a plurality of types of products in the plurality of factories. Device, the information processing device is a means for determining a required production amount for each plant type, for each type of plant based on the total sales forecast for each type and a preset distribution parameter, and a preset constraint and Means for creating a daily production plan for each of the plurality of varieties based on the required production amount for each of the varieties for each of the factories and for each period, wherein the plurality of factories are created by the information processing apparatus. It is characterized by having means for referring to a production plan for each line and each day through a network.

[0025]

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings. The following embodiment is an example in which the present invention is applied to a beer production plan.

FIG. 1 is a diagram schematically showing a configuration of a production management system according to a preferred embodiment of the present invention. The production management system includes a computer 11 of the production unit 10,
The database 20, the computer 31 of the sales department 30, the computer 41 of the distribution department 40, and a plurality of factories (factory A, factory B, factory C, factory D ...) 50, 60, 70, 80 ...
. Are connected via the network 10. The computers 51, 61, 71, 81,.
The network 10 may be connected to a computer of another department, for example, a purchasing department.

The network 10 can be constituted by, for example, a communication line capable of two-way communication (for example, the Internet or a dedicated line). Each department (for example, production department)
A plurality of computers may be arranged, and in this case, the plurality of computers may be connected by a communication line such as a LAN.

Each of the computers 11, 31, 41, 51,
61, 71, 81... Are typically general computers such as personal computers, for example, a microprocessor (CPU), a memory (eg, a RAM,
ROM, hard disk, etc.), communication interface (eg, modem, etc.), display, speaker, keyboard, mouse, etc.

A production plan creation program 11a is installed in the computer 11 of the production unit 10.
A production plan is created according to the program 11a. That is, the computer 11 functions as a production plan creation device in this production management system. Program 11a
Can be distributed while being stored in a memory medium such as a CD-ROM.

The database 20 stores various data relating to production management (including production planning). The computer 31 of the sales department 30 can be used to input, for example, information on sales targets, information on campaigns, and the like. The computer 41 of the distribution unit 40 can be used, for example, for inputting information on expected sales and sales results. The computers 51, 61, 71, 81... Of the factories 50, 60, 70, 80. Is used to refer to the production plan created by the user through the network 10.

A plurality of factories 50, 60, 70, 80,...
Are, for example, a block A including factories 50 and 60, a block B including factory 70, a block C including factory 80, and so on.
Can be divided into More generally, all factories belonging to this production management system are divided into a plurality of blocks each including one or a plurality of factories.

In this embodiment, the production plan includes a ratio (an example of an allocation parameter for allocating an expected sales),
It can be created based on the sales prospects, masters, and other settings for each product type in a region (for example, the whole country) managed by this production management system. These ratios, sales prospects, masters, and the like can be set by an operator or the like prior to creation of a production plan.

The ratio can include, for example, a block ratio, a seasonal ratio, a day of the week ratio, and the like.

The block ratio is a ratio between the production amount to be allocated to the corresponding block and the production amount in the whole country. For example,
Factories nationwide are Block A, Block B and Block C
If it is divided into two blocks, blocks A, B,
The block ratio for C is, for example, 50%, 30%,
20%, and the sum of the three block ratios is 100%. That is, in block A, 50% of the national production volume, and in block B, 30% of the national production volume.
%, Block C means that 20% of the national production is produced.

The season ratio is a ratio between the production amount of the corresponding block in the corresponding block (early, middle, and late) and the production amount in one month. The seasonal ratios of early, middle, and late are set, for example, to 50%, 30%, and 20%, and the sum of the three seasonal ratios is 100%. This means that in the corresponding block, 50% of the corresponding month's production in early
This means that 30% of the production in the corresponding month is produced in the middle and 20% of the production in the corresponding month is produced in the late.

The day-of-week ratio is a ratio between the production amount of the corresponding day (Monday to Sunday) in the relevant week and the production amount of one week. The day-to-day ratio of Monday to Sunday is, for example, 2
0%, 20%, 15%, 15%, 30%, 0%, 0%, etc., and the sum of the seven day-of-week ratios is 100
%.

In this embodiment, the production is planned by classifying the products into daily managed varieties managed on a daily basis and seasonally managed varieties managed on a seasonal basis.
It should be noted that since the production of the seasonally managed varieties is planned in seasons, it is not necessary to set the day-of-week ratio.

For example, the nationwide sales forecast is based on the sales results of the previous fiscal year, and takes into account the planning of campaigns, the results of market surveys, etc., and any of the production department 10, sales department 30, distribution department 40, and other departments. Alternatively, it can be created with the cooperation of all or some of them. Estimates of sales nationwide are created for each product type.

The master includes various restrictions on production. Here, the constraints include, for example, the following items. (1) Restriction on line that can be manufactured by type The restriction on line that can be manufactured by type is a restriction on a line that can be used to manufacture the corresponding type. (2) Restriction on the number of brands by factory Restriction on the number of brands by factory is a restriction on the number of brands that can be manufactured at the relevant factory on the same day. (3) Brand priority restriction Brand priority restriction is a restriction on the priority of the brand to be produced. (4) Line type container type priority restriction Line type container type priority restriction is a restriction on the priority of the type of container handled in the corresponding line, and is determined for each line. (5) Type-specific line priority restriction Type-specific line priority restriction is a restriction on the priority of the line that produces the relevant type. (6) Remodeling pattern restriction The remodeling pattern restriction is a restriction on a pattern that can change the type (for example, the type of container, the type of package, and the like). For example, there is a restriction that the container A can be switched from the container A to the container B on the corresponding line, but the container A cannot be switched from the container A to the container C. (7) Liquid change time restriction Liquid change time restriction is a restriction on the time required when changing the liquid (brand). (8) Remodeling time constraint The remodeling time constraint is a constraint on the time required to change the mold. (9) Type change frequency restriction The type change frequency restriction is a restriction on the number of times the type is changed. (10) Daily Maximum Line-Count Restriction The daily line-maximum direct-number constraint is a constraint on the maximum direct number defined for each day and for each line. Nao is one, two
It is a work style of direct shift, third shift, etc. (11) Transfer priority restriction between factories Transfer priority restriction between factories is a restriction when a production plan is transferred from one factory to another factory. (12) Inventory restrictions Inventory restrictions are restrictions on the amount of inventory to be secured.
The inventory constraint is given for daily managed varieties, for example, by converting the minimum, appropriate, and maximum values of stock quantity to be secured into days, and for seasonally managed varieties, for example, the ratio to the expected seasonal sales, etc. Can be given by (13) Other restrictions Other restrictions include, for example, restrictions on block division, restrictions on factories belonging to each block, restrictions on lines of each factory, restrictions on brand types,
There are restrictions on types, types of containers, and the like.
Here, the constraints may include all items to be considered when manufacturing a product.

FIG. 2 is a diagram showing an outline of processing by the production plan creation program 11a installed in the computer 11 of the production unit 10. Steps S101 to S1
03 is an input process executed prior to execution of step S104 (production plan creation process).

In step S101, the computer 11
Sets various ratios according to instructions from an operator or the like. In step S102, the computer 11 sets a sales forecast for each product type in the whole country according to instructions from an operator or the like. In step S103, the computer 11
Sets a master according to instructions from an operator or the like. Here, the instruction from the operator or the like may be given from another computer connected to the network 10.

In step S104, the computer 11
Creates a production plan based on the information set in steps S101 to S103.

In step S105, the computer 11
Outputs the production plan created in step S104. The output destination may be, for example, a display of the computer 11, or a printer connected to the computer 11 or the network 10. The created production plan is preferably stored in the database 20. In this case, the sales department 30, the distribution department 40, and the factory 5
By accessing the database 20, an operator of a computer such as 0, 60, etc. can refer to all or a part of the production plan. As the output destination, in addition to the database 20, the sales department 30, the distribution department 4
Computers such as 0, factories 50, 60, etc. can also be designated. At each factory, the created production plan is examined, and if there is a problem, the production unit 10 can be notified to that effect using, for example, the network 10.
Here, it is considered that the problem is mainly caused by an error in the setting of the ratio, the expected sales in the whole country, and all or some of the masters. Therefore, when there is a problem in the created production plan, the setting that caused the problem may be appropriately changed (steps S101 to S103), and the production plan may be created again (step S104).

FIG. 3 is a diagram showing details of step S104 (production plan creation processing) in FIG. First, step S
In 201, the computer 11 apportions (proportionally distributes) the sales prospects for each type to all blocks (block A, block B, block C,...) Based on the block ratio for each type. For example, the sales prospect of a certain product is 1000 pieces,
If the block ratio for block A is 30%,
In block A, 300 production plans of the product are allocated. As a result, a sales forecast is created for each product type and each block.

In step S202, the computer 11
In the varieties that have been apportioned in step S201, the daily sales varieties of the varieties managed by the varieties are distributed on a daily basis based on the seasonal ratio and the day of the week varieties (the seasonal ratio corresponding to the expected sales by varieties block). And the applicable day-of-week ratio). As a result, for each type of daily management, a sales forecast for each type of block for each day is created.

In step S203, the computer 11
In the varieties that have been apportioned in step S201, for the seasonally managed varieties, based on the seasonal ratio, the sales prospects for each type of block are apportioned for each season (the expected sales for each type of block are multiplied by the seasonal ratio). As a result, sales forecasts for the seasonally managed varieties are created for the varieties, the blocks, and the seasons.

In step S204, the computer 11
Calculates the required production amount by type, by block, and by day to secure the safety stock for the daily management type, based on the sales forecast and inventory constraint by type, by block, and by day created in step S202. Step S203
Based on the sales forecast and stock restrictions by type and block by type created in the above, the required production amount by type and block by type to secure the safety stock amount for the seasonally managed type is calculated.

More specifically, for a daily managed variety, if the inventory constraint is given by converting the minimum, appropriate, and maximum of the stock amount to be secured into days n, the safety stock amount at the end of the day is: For example, (the safety stock amount at the end of the day) = (sum total of expected sales for the previous n days).

The required production amount for the day is, for example, (required production amount for the day) = (safety stock amount at the end of the day) +
(Estimated sales on that day)-(Inventory volume at the end of the previous day).

On the other hand, when the inventory restriction is given by the inventory ratio for the seasonally managed varieties, the safety stock amount at the end of the season is, for example, (the safety stock amount at the end of the season) = (the expected sales amount of the next season) ) × (inventory ratio).

The required production amount in the season is, for example, (required production amount in the season) = (stock amount at the end of the season) + (expected sales in the season) − (stock amount at the end of the previous season). Given.

In step S205, the computer 11
Calculates the required production amount by type, factory, and day for the daily managed variety based on the required production amount by type, block, and day calculated in step S204, and calculates the product calculated in step S204. Based on the required production amount for each type of block and for each season, the required production amount for each type of plant and each season for the managed variety for each season is calculated.

Here, when only one factory belongs to the block, the required production amount for each type of block and each season and the required production amount for each type of block and each season are directly used for each type of plant and each day. The required production amount can be determined according to the production amount, the type, the factory, and the season.

On the other hand, when a plurality of factories belong to a block, for example, the required production amount for each type, for each block, for each day,
The required production amount for each type and for each block can be distributed to the plurality of blocks according to a predetermined rule (distribution parameter). In this case, typically, the required production amount for each type of block and each day and the required production amount for each type of block and each season can be apportioned to the plurality of blocks at a predetermined ratio (for example, an equal ratio). .

In step S206, the computer 11
Is a line-by-line daily production plan that can achieve the required production amount by type and factory and the required production amount by type and factory at step S205 so as to satisfy various constraints. Is created for each factory.

FIG. 4 is a diagram showing the details of step S206 of FIG. 3 (processing for creating a production plan for each line and day).

First, in step S301, the computer 11 piles up (provisionally assigns) the required production amount of the seasonally managed variety on the first priority line, and sequentially collapses the required production amount for the violation of the constraint (repeatedly). Assignment). At this time, if the required production amount cannot be landslide in the relevant factory and the landslide cannot be performed in the corresponding block, the computer 11 performs landslide to another block (assignment to another block (inter-block transfer)).

In step S302, the computer 11
, The required production amount of the daily managed variety is piled up on the line of the first priority, and the required production amount for the violation of the constraint is sequentially collapsed.

In step S303, the computer 11
In the required production amount of the daily management type, the part that violates the constraint is crushed to another block (inter-block transfer).

As a result, a production plan for each product line is created for each line. The computer 11 can display the created production plan on a display, output it from a printer, and save it in the database 20.

Here, if there is a defect in the created production plan, the computer 11 may execute the production plan creation program again by correcting the restrictions, the expected sales, and the like.

FIG. 5 is a diagram conceptually showing piles.
In FIG. 5, symbols represented by two English characters (for example, A
A) shows a variety. Here, the first letter of the alphabet indicates the brand, and the last letter of the alphabet indicates the container. Of these varieties, AA, AB, AC, and AD are daily managed varieties, AE, AF,
BA, BD, CC and CB are seasonally managed varieties.

C1 to C4 indicate lines. Also,
The “required production amount by factory” is an example of the required production amount of one factory created in step S205 within a predetermined period, and the “prioritized line by product type” is an example of a constraint.

FIG. 5 conceptually shows a pile of seasonally managed varieties. In this example, the required production amount of the seasonally managed variety to be produced in the middle of July is the first day of the season (July 11).
In the first priority line. Such accumulation is called pile-up (temporary allocation). The stacking of the daily managed varieties is preferably performed after the seasonal managed varieties are stacked and crushed.

FIG. 6 is a diagram conceptually showing a landslide of a seasonally managed variety. In the example shown in FIG. 6, if there is a constraint violation on the lines C1 and C3 (for example, the number of types of brands produced on the same line per day), for example,
As shown in (b), the brand unit (in (b), the varieties CB and CC of the brand C) is assigned to the lines C1 and C
Reassign to 3. Constraint violations after this reassignment (for example,
If there is an excess of the production capacity), for example, as shown in FIG.
Thus, part of the variety AF (excess of the production capacity) assigned to the line C2 on July 11 was reassigned to the line C2 on July 12 and also assigned to the line C3 on July 12. Part of the product type CC (excess of production capacity) will be reallocated to line 3 on July 13. Such reassignment is called landslide.

The mountain landslide of the daily management variety was also
This can be done in the same way as a seasonally managed variety. Here, in the preferred embodiment of the present invention, after the seasonal management varieties are piled up and collapsed, the daily management varieties are piled up and collapsed. In a preferred embodiment of the present invention, the landslide of daily managed varieties is first performed in the same factory on the same day (first stage landslide), and then performed in the same factory on another day. (Second stage landslide).

FIG. 7 is a diagram showing an example of a production plan of the daily managed variety before the second-level collapse (ie, immediately after the first-level collapse). In the production plan at the stage shown in FIG. 7, if the production capacity is not exceeded, a proper inventory amount can be ensured in the plan, but if the production amount exceeds the production capacity, As shown in FIG. 7, the inventory amount may be lower than the appropriate inventory amount. As described above, when the amount is less than the appropriate stock amount, the excess amount may be collapsed on another day to increase the stock amount to the appropriate stock amount in some cases. This will be described with reference to FIG.

FIG. 8 is a diagram conceptually showing a second-stage mountain landslide of daily managed varieties. In the second stage of the landslide, the excess amount of the production capacity is sequentially landslide the next day to raise the inventory amount to the appropriate inventory amount. In this way, a method in which the excess of the production capacity is successively collapsed on the next day is defined as a ball-throw method.

The landslide described above with reference to FIGS. 5 to 8 is an example of landslide backward in time, and this is defined as a landslide caused by falling backward or backwards. On the other hand, the landslide can be performed forward in time. This is defined as moving forward or moving forward.
FIG. 9 is a diagram conceptually illustrating that the daily managed varieties are brought forward. Incidentally, since the seasonally managed varieties are piled up on the first day of the season, preferably (when other landslides can be produced), landslides should not be carried out by moving forward.

FIG. 10 is a diagram conceptually showing inter-block transfer. The block-to-block transfer refers to transfer (re-allocation or landslide) of a part of the production plan from the factory of the own block to the factory of another block. In the example shown in FIG. 10, the excess of the production capacity is transferred to the factory of the other block while moving forward the daily managed variety. Specifically, in the example shown in FIG. 10, the type AD assigned to the line C4 of the factory A on July 13 is changed to the line C2 of the factory C in the other block on the same day.
A part of the required production amount of the variety AA which has been transferred to the line C3 of the factory A on July 12 is transferred to the line C1 of the factory C of the other block on the same day, and The required production amount of the product type AA which has been moved forward to the line C3 is transferred to the line C1 of the factory C in the other block on the same day.

Hereinafter, S301, S302, S30 of FIG.
A specific example 3 will be described.

[Pile of managed varieties according to season, pile collapse, transfer between blocks (S301)] (S401) In step S401, the computer 11
Accumulates the required production amount of each seasonal managed variety on the first priority line of the season or the first priority line on the designated date in accordance with the type-specific line priority constraint.

(S 402) In step S 402, the computer 11 crushes the required production amount of the seasonally managed varieties piled up in the factory on the same day. That is, the computer 11 lands the constraint violation of the seasonally managed variety having a constraint violation (for example, an excess of production capacity due to the maximum number constraint violation) on another line of the same factory.

(S 403) In step S 403, if the computer 11 cannot adjust the production plan in the same factory in step S 402, the computer 11 compares the violation of the constraint with another factory in the same block (in the same block). (When there is another factory in the factory)).

(S 404) In step S 404, the computer 11 causes a constraint violation in step S 402 and S 403 (for example, a production capacity excess due to a maximum direct number constraint violation, a brand number constraint violation, a type change number constraint violation, etc.) within the same day. If the production plan cannot be adjusted by using, the part that violates the constraint is postponed.

(S 405) In step S 405, the computer 11 lands a constraint violation that cannot be adjusted in the production plan by executing step S 404 to another block factory (inter-block transfer).

(S 406) In step S 406, the computer 11 adjusts the constraint violation, which cannot be adjusted by the execution of step S 405, ahead of schedule.

[Pile of daily managed varieties and landslides (S30
2)] (S501) In step S501, the computer 11
Accumulates the required production amount of the daily managed varieties with respect to the line having the first priority on the corresponding day according to the type-specific line priority constraint.

(S 502) In step S 502, the computer 11 lands the required production amount of the piled daily management varieties in the factory on the same day. That is, the computer 11 collapses the constraint violation of the daily management type having the constraint violation (for example, the production capacity excess due to the maximum number constraint violation) to another line of the same factory.

(S 503) In step S 503, if the production plan cannot be adjusted in the same factory in step S 502, the computer 11 compares the constraint violation with another factory in the same block (in the same block). (When there is another factory in the factory)).

(S 504) In step S 504, the computer 11 causes a constraint violation in step S 502 and S 503 (for example, a production capacity excess due to a maximum direct number constraint violation, a brand number constraint violation, a type change count constraint violation, etc.), and the computer 11 within the same day. If the production plan cannot be adjusted by using, the part that violates the constraint is postponed. At this time, the computer 11 adjusts the amount of backward movement so that the safety stock amount in the block does not fall below the lower limit.

[Transfer between blocks of daily management type (S30
3)] This inter-block transfer is executed when there is a daily management type that is out of stock as a result of execution of step S302.

(S 601) In step S 601, the computer 11 forwards, to the factory in the other block, the daily managed products that are out of stock while moving forward.

(S 602) In step S 602, if the out-of-stock condition is not resolved by the execution of step S 601, the computer 11 transfers the other daily management types to other blocks while moving forward,
The production capacity within the own block is secured, and the daily managed varieties related to the stock-out are destroyed in the line where the production capacity is generated.

(S 603) In step S 603, if the out-of-stock condition is not resolved by the execution of step S 602, the computer 11 determines whether or not the daily-managed products having a sufficient stock (daily-managed products that exceed the lower limit of the stock) ) To reduce the amount of production, and thereby destroy the daily management varieties related to out-of-stock in the line where the production capacity has arisen.

If the stock-out occurs even after the above adjustment, the computer 11 outputs a warning together with the created (incomplete) production plan.

The above description relates to a method of creating a production plan based on actual constraints, determinate ratios, and sales prospects. It is also possible to simulate whether proper production is possible. If this simulation function is used, it is possible to determine in a short time whether or not all products including the new product can be appropriately produced when a new product is introduced.

The above description relates to an example in which a product plan is created by classifying product varieties into daily managed varieties and seasonal managed varieties, but this takes into account the specificity of the beer production plan. . Needless to say, freshness is extremely important in beer. Therefore, for products that are expected to be sold in large quantities, do not have unnecessary inventory,
In addition, it is preferable to produce only a necessary amount on a daily basis so as not to fall below expected sales. On the other hand, for products that are expected to sell only a small amount (for example, products with high palatability), if only the required amount is produced every day, the efficiency of line usage will decrease, so the seasonal unit will be It is preferable to collectively produce necessary products on the first day or the like. Typically, the former variety is a daily managed variety, and the latter is a seasonally managed variety. Here, for a period shorter than the season,
Alternatively, products can be managed in units longer than the season.

The effects of the preferred embodiment of the present invention will be described below.

First, according to the preferred embodiment of the present invention, a product production plan can be obtained easily and quickly without having to be familiar with factory facilities, personnel, manufacturing processes, and the like.

Second, according to the preferred embodiment of the present invention, when the production capacity is changed (for example, a line is broken) or when the expected sales or the ratio are changed (for example,
In addition, the production plan can be re-created only by changing the necessary parameters among the master, the expected sales, and the ratio, and the man-hour for the production plan can be greatly reduced.

Third, by using the simulation function, for example, it is possible to quickly and accurately confirm whether or not a change in business policy (for example, replacement of a product) is possible. More specifically, for example, when a new product is introduced, it is possible to quickly and accurately determine whether or not all products including the product can be appropriately produced.

Fourth, by transferring a production plan between blocks or between factories, the production capacity of a plurality of factories can be effectively used.

[0094]

According to the present invention, for example, the production planning can be speeded up.

[Brief description of the drawings]

FIG. 1 is a diagram schematically showing a configuration of a production management system according to a preferred embodiment of the present invention.

FIG. 2 is a diagram showing an outline of processing by a production plan creation program installed on a computer of a production unit.

FIG. 3 is a diagram showing details of a production plan creation process of FIG. 2;

FIG. 4 is a diagram showing details of processing for creating a production plan for each line in FIG. 3;

FIG. 5 is a diagram conceptually showing a pile.

FIG. 6 is a diagram conceptually showing a landslide of a seasonally managed variety.

FIG. 7 is a diagram illustrating an example of a production plan before a second-level mountain landslide of daily managed varieties.

FIG. 8 is a diagram conceptually showing a second-level mountain landslide of a daily managed variety.

FIG. 9 is a diagram conceptually showing that a daily managed variety is moved forward.

FIG. 10 is a diagram conceptually showing inter-block transfer.

Claims (23)

[Claims] 1. A production plan creating method for creating a production plan for producing a plurality of types of products in a plurality of factories each having a plurality of lines by using an information processing apparatus. A step of determining the required production amount for each type of plant and each day based on the sales forecast and the preset distribution parameters; and Creating a daily production plan for each product line by line. 2. The step of creating a daily production plan for each line, wherein the required production amount for each type of plant and each day is set to a predetermined priority order for a plurality of lines of a corresponding factory. The method according to claim 1, further comprising a step of assigning the production plan based on the information. 3. The step of creating a daily production plan for each line, comprising: setting a required production amount for each type of factory for each day to a first constraint set in advance for a plurality of lines of a corresponding factory. And a crushing step of crushing a constraint violation that violates a preset second constraint in the required production amount laid in the stacking step. The production plan creation method according to claim 1. 4. The production plan creation method according to claim 3, wherein the landslide step includes a step of landslide the constraint violation to another line of the same factory on the same day. 5. The production plan creation method according to claim 3, wherein the landslide step includes a step of landslide the constraint violation to another factory on the same day. 6. The production plan creation method according to claim 3, wherein the landslide step includes a step of landslide the constraint violation on another day of the same factory. 7. The production plan creation method according to claim 6, wherein the landslide step includes a step of sloping down the constraint violation portion by moving it backward. 8. The production plan creating method according to claim 6, wherein the landslide step includes a step of landslide by moving forward the constraint violation. 9. The production plan creation method according to claim 3, wherein the landslide step includes a step of landslide to another factory while moving forward the constraint violation. 10. A production plan creating method for creating a production plan for producing a plurality of types of products in a plurality of factories each having a plurality of lines by using an information processing apparatus, comprising: A step of determining a required production amount for each type of plant and each period based on expected sales and a preset distribution parameter; and Creating a daily production plan for each product line by line. 11. The step of creating a daily production plan for each line comprises: setting a required production amount for each type of plant and for each period according to a predetermined priority order for a plurality of lines of the relevant factory. The method according to claim 10, further comprising a step of allocating the production plan based on the information. 12. The step of creating a line-by-line and day-by-day production plan includes: calculating a required production amount for each type of plant and for each period of time for a plurality of lines of a relevant factory on a specific day of the relevant period. A stacking step of stacking based on a preset first constraint, and a crushing step of crushing a constraint violation part of a required production amount stacked in the stacking step that violates a preset second constraint. The production plan creation method according to claim 10, comprising: 13. The production plan creating method according to claim 12, wherein the landslide step includes a step of landslide the constraint violation to another line of the same factory on the same day. 14. The production plan creation method according to claim 12, wherein the landslide step includes a step of landslide the constraint violation to another factory on the same day. 15. The production plan creation method according to claim 12, wherein the landslide step includes a step of landslide the constraint violation in the same factory for a corresponding period. 16. The production plan creation method according to claim 15, wherein the landslide step includes a step of sloping down by violating the constraint violation. 17. The production plan creation method according to claim 12, wherein the landslide step includes a step of landslide by moving the constraint violation portion forward in a previous period. 18. The production plan creation method according to claim 1, wherein the product includes beer. 19. An information processing apparatus for creating a production plan for producing a plurality of types of products in a plurality of factories each having a plurality of lines, wherein an expected total sales and a preset distribution of each type are provided. Means for determining a required production amount for each type of plant based on parameters; and a daily limit for each of the plurality of types based on constraints set in advance and the required production amount for each type of plant. Means for creating a production plan of the information processing apparatus. 20. An information processing apparatus for creating a production plan for producing a plurality of types of products in a plurality of factories each having a plurality of lines, wherein an overall sales forecast and a preset distribution for each type are provided. Means for determining the required production amount for each type of plant and each period based on parameters; and for each day of each line for the plurality of types based on preset constraints and the required amount of production for each type of plant and each period. Means for creating a production plan of the information processing apparatus. 21. Any one of claims 1 to 18
A memory medium storing a program for causing an information processing apparatus to execute the production plan creation method described in the section. 22. A production management system, comprising: a plurality of factories each having a plurality of lines; and an information processing device for creating a production plan for producing a plurality of types of products in the plurality of factories. The information processing apparatus includes: means for determining a required production amount for each type of plant and for each day based on an expected total sales for each type and a preset distribution parameter; Means for creating a daily production plan for each of the plurality of varieties based on the required production amount for each day, and wherein the plurality of factories are arranged for each of the lines produced by the information processing apparatus. A production management system comprising means for referring to a production plan through a network. 23. A production management system, comprising: a plurality of factories each having a plurality of lines; and an information processing device for creating a production plan for producing a plurality of types of products in the plurality of factories. The information processing apparatus includes: means for determining a required amount of production for each type of plant and for each period based on an expected total sales for each type and a preset distribution parameter; Means for creating a daily production plan for each of the plurality of varieties based on the required production amount for each of the different periods. A production management system comprising means for referring to a production plan through a network.