JP2002123311A - Device and method for material management and storage medium with computer program implementing the same managing method recorded thereon - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make material plans preparable for every production place with the same component numbers and the same component table concerning a device and a method for managing materials and a recording medium with a computer program for the method. SOLUTION: A necessary amount holding means is provided for recording and securing necessary amounts of materials together with the names of the material and the names of places where the materials are used. Retrieval from the necessary amount holding means is performed by using material names and place names to find necessary amounts by the material names, place names and plan ordering, and ordering information on the materials by the place names is generated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a material requirement plan for each production location.
The present invention relates to a material management device and a management method for assisting a computer using a computer to perform the t-planning, and a storage medium storing the program.

[0002]

2. Description of the Related Art Conventionally, when procuring materials required at a plurality of production sites (assembly lines, etc.), the amount of the materials required at the production sites is summed up for each material using a computer, and the total required amount is reduced. Asked and ordered. Hereinafter, a case where the material is a part will be described as an example. For example, when 100 and 200 parts X of the same part are required on the production line A and the production line B, respectively, a total of 300 parts is obtained as the total requirement of the part X, and 300 parts are ordered from the part manufacturer. I was At this time, if the minimum order unit of the company that receives the order of the part X is 500 pieces, the order is made with 500 parts X.

FIG. 10 is an explanatory diagram of the prior art.

[0004] In FIG. 10, a part X and a screw A having a sticker on which a letter “front” is printed are attached to the head of the screw A.
A conventional material management method will be described for a part Y having a sticker on which the letter “L” is printed on the head of the part Y. Part X
The total required amount of the screw A is obtained from the required amount of the component Y and the required amount of the part Y, and the screw A is ordered.

Further, FIG. 10 shows a case where a raw material member D for manufacturing the screw A is procured from the total required amount of the screw A, the raw material member D is provided, and the manufacture of the screw A is ordered from a screw processing company. Shows the ordering plan.

[0006] In FIG. 10, reference numeral 111 denotes a part X, which has a seal “front” attached to the head of the screw A. Reference numeral 112 denotes a component Y, which has a seal “rear” attached to the head of the screw A. 113 is a screw A.
Reference numeral 114 denotes a raw material member D for forming the screw A.

Reference numeral 121 denotes a material total requirement plan, which is the required amount of the screw A obtained from the necessity of the part X.
The period 2 indicates that 500 parts A (serial number X01) are required, and the period 3 indicates that 2,000 parts A (serial number X02) are required. Is determined by the serial number excluding). Reference numeral 122 denotes a material total requirement plan, which is the required amount of the screw A obtained from the necessity of the part Y. Period 3 requires 1,000 screws A (serial number Y01), period 5 requires 500 screws A (serial number Y02), and period 6 requires 500 screws A (serial number Y03) It represents that. In addition, when the screw A is provided with the raw material member D and requested to be manufactured, the screw A is delivered one day later (the lead time LT of the screw A = 1).

Reference numeral 123 denotes a material requirement planning table, which is the total requirement of the screw A, the order backlog (the amount of the screw that has already been ordered for production but has not been delivered), the available stock, and the net requirement (stock). , The order quantity which needs to be actually ordered in consideration of the order remaining, etc.), and the order to be ordered (the order quantity in consideration of the ordering conditions of the ordering party or the ordering conditions of the supplier) for each period. For example, the method of calculating the order quantity on the ordering party side is a lot summarizing method. For example, net requirements for two periods are put together to make a single requirement. The condition of the ordering party is, for example, a method for rounding off the ordering amount, and the ordering amount is rounded up to the order receiving unit on the order receiving side. For example,
The order receiving unit of the order receiving side is 500 pieces and the net requirement is 2,300
If so, order 2,500.

Reference numeral 124 denotes a total material requirement plan.
This is a material total requirement plan developed in stages, in which the total required amount of components (the raw material member D in FIG. 10) at one level lower than the screw A is obtained. In the case of FIG. 10, since the lead time of the screw A is one day, the screw A is 2,500
Therefore, in period 2, the raw material member D for 2,500 screws A is obtained as the required amount. Further, the required amount of the screw A in the period 5 and the period 6 is rounded, and the raw material member D for the 1,000 screw in the period 4 is obtained as the required amount from the ordering order of the screw A of 1,000.

A conventional method for planning the total required amount of screws A will be described with reference to FIG.

[0011] In period 1, there are 200 stocks in which screws can be used. Also, in period 2 the order remains (screw A with order number A01).
Are ordered), and 1,100 screws A are delivered. Therefore, although 1,000 screws are required in period 2, 1,100 screws are delivered, so the available stock is 30
It becomes zero.

Further, 2,500 screws A are required in period 3. Since the available stock in period 3 is 300 pieces,
The net requirement is 2,200. On the other hand, the ordering method is 50
Since the rounding method is used in units of 0 units, the order to be ordered in period 3 is 2,500 (order number A02). Further, the net required amount of the screw A in the period 5 and the period 6 is 500 pieces, respectively. Since the rounding method of two periods is adopted, 1,000 orders to be ordered in period 5 (order number A03)
Becomes

Further, the total required amount of the raw material member D is calculated by performing the development one step lower. Since the scheduled order of screw A in period 3 is 2,500 and the scheduled order of screw A in period 5 is 1,000, the lead time of screw A is one day. In order to be able to deliver 2,500 screws A and 1,000 screws A in period 5, the total required amount of raw material members D
It is determined as 0 screws and 1,000 screws A in period 5. Then, in period 2, the raw material member D for 2,500 screws
And request the screw manufacturer to manufacture the screws. As a result, 2,500 screws are delivered from the screw manufacturer in period 3.

FIG. 11 shows a conventional technique, and is a flowchart of a conventional material management apparatus. The operation of FIG. 11 will be described (see FIG. 10).

S1 is an initial setting, in which required quantities of lower-order parts are developed based on a production plan. Search for configuration files of parts X and Y (X is composed of screw A and seal “front”, and Y is product configuration file that records that it is composed of screw A and seal “front” (see FIG. 2)) Then, on the basis of the net change of the parts X and Y, the parts of the lower hierarchy develop the required amount of the seal “A”, the seal “B” and the screw A. S2 is an extraction process in which the initially set components are extracted for each item in ascending order of the low level code.

It is determined whether or not the extraction processing of all the items not to be expanded in S3 has been completed.
The following processing is performed. In S4, the total requirement plan of the item unit (the screw A in FIG. 10) (reference numerals 121, 12 in FIG. 10)
Create 2). Total material requirement plan 121 for screw A from part X, total material requirement plan 12 for screw A from part Y
2 (the contents of 121 and 122 are respectively recorded in records), and the total required amount of the screw A is obtained for each period.

At S5, a net requirement is planned (a net requirement is obtained from the material requirement planning table 123 for the screw A in FIG. 10). Round the lot in S6 (in the case of FIG. 10,
The required amount of screw A for period 5 and period 6 is summarized). S7 Ordering condition (if the ordering unit is 500 units, for example, 40
If the order quantity of the supplier is 500 pieces, if the order quantity of the supplier is 500 pieces, the lot is rounded in the same manner as described above and the net required quantity meets the condition. Create an order to be ordered based on the order (arrangement). In step S8, the required quantity of the lower-order part is developed (one-step development). In the case of FIG. 10, after the required amounts of the screw A, the seal “A”, and the seal “B” are determined, a material requirement plan of the screw A is made.
With respect to the lower order configuration (raw material member D), the required quantity is determined from the scheduled order of the screw A.

[0018]

In the conventional material management method as described above, ordered materials are delivered in parts. Therefore, when parts are required at a plurality of production locations, it is necessary to open the received package, arrange the number of components at each shipping destination (production location such as a line), and release the components. For example, in the case of the example of FIG.
When 1,100 items were delivered, 800 out of the box was unpacked.
The unit and the 200 units in the warehouse are supplied together to the part X production location. Then, the remaining 300 pieces are stored in a warehouse.
Next, when 2,500 parts of the planned order A02 arrive in period 3, 300 parts of the stock in the warehouse and 1,700 pieces of the received ordered goods A02 are taken out, and 2,000 parts are taken out. The individual is supplied to the production place of the part X. Next, 5 items from the order A02
00 pieces are prepared and supplied to the part Y production site. Remaining 3
00 pieces are stored in a warehouse.

Next, when 1,000 pieces of the order A03 to be ordered are received during the period 5, the packing is opened and 300 pieces of the stock are stored.
The individual and A03 are opened, 200 are taken out, and 500 are supplied to the part Y production place. The remaining 700 A03s are stored in the warehouse. The next day, 500 parts are taken out of the warehouse and supplied to the production site of the part Y.

As described above, the conventional material management requires a very complicated operation, and the burden on the operator is large.
A major drawback of the conventional material management is that, since the management is performed on a part-by-part basis, it is necessary to sort and supply each of the production locations after opening the received luggage.

As a method of solving this problem, it is conceivable to include a production location in a part number and to cope with the problem. However, this method raises the following new difficult problems.

(1) The number of items and parts tables increases, and the processing time of computer management increases.

(2) When a design change occurs, it is necessary to correct the parts table for each production location, and the processing becomes cumbersome.

(3) When the allocation of production lines is changed or the number of suppliers of outsourced products is increased, changes must be made so as not to cause inconsistencies between the parts tables.

(4) In the case of a part corresponding to a plurality of lines or a part to be purchased by a plurality of companies, a higher-order item of the part must have a lower parts list for a plurality of suppliers.

(5) Even for the same item, since the item number is different for each production location, material management becomes complicated.

It is an object of the present invention to provide a material management apparatus and method capable of formulating a material plan for each production location with the same part number and the same parts table, and a storage medium storing the computer program.

[0028]

According to the present invention, for a material required at a site (a production site requiring the material), the name of the material, the required amount, and the site name are recorded and held.
Then, based on the recorded quantities of the site name and material name,
Searching by material name and site name, the total requirement by site name and material name was obtained, site name was added, and materials were ordered.

When a material has a hierarchical relationship between a high-order item and a low-order item, the delivery destination of the necessary material of the low-order item (a destination to which the product is supplied when it is received) is automatically set as the delivery destination of the high-order item. I did it.

The delivered materials are recorded with the storage destination as each production site and are received. Therefore, the received materials (parts) need only be transported to the recorded production site without opening at the place where they were received, thereby greatly reducing the labor for receiving management. Since the management of remaining orders and inventory management can be performed for each production site, the amount of common inventory management can be reduced and inventory management work can be reduced.

Further, since the delivery destination of the lower item is simply switched to the production location of the upper item, material management of the lower item can be performed by common processing. Further, since the same material table can be used for materials in different production locations, high-speed computer processing can be performed without increasing the number of documents to be managed.

[0032]

FIG. 1 shows a first embodiment of the present invention, which is an embodiment for explaining a basic concept of the present invention.

In FIG. 1, reference numeral 1 denotes a material requirement plan, which records the required amount at the production location and the production location for each material, the production location inventory, and the order backlog (usually created as a record in a database). , Stored in storage means). 10 material X to be used in the production locations P _A, period requires a material X T, the required amount X _A of the production location P _A, stock X _RA of materials X of the production location P _A, order of production location P _A X remaining
Indicates a record that holds _RA . 11 Material X used in production location P _B, the period T (time period T which requires materials X is
Represents the date that must be warehousing the material), represents the record that holds the required amount X _B in the production location P _B, of the material X in the production location P _B stock X _RB, ordering remaining X _RB production location P _B . FIG.
Shows a common stock is X _RB = 0 state orders remaining X _RA = 0, Material X production location P _B of the material X in the production location P _A.

Reference numeral 3 denotes a common stock held in the storage means, and holds a stock amount of each material common to the production site. Figure 1 is a common inventory of materials X represents a state which is X _R.

Production place P_AThe total requirement for material X
Therefore, the record of the material requirement plan 1 is_A,
Search for material X, find the sum, production location P_ATotal requirements
Ask for. At this time, referring to the common stock 3, the production place P_A
Inventory X allocated to material X _RAnd calculate the number of inventory allocations.
You. Thus, the production place P in the period T_AResources
Required amount X of material X_A, Order remaining 0, inventory allocation X_R， Production site
Place stock X_RAAnd the net required quantity X_TA= X_A-X_RAsk for
You. Also, the production place P_AThe record of the total requirement of the production site
Place P_AIs recorded as the delivery destination. The common stock is X_R
Is set to 0.

[0036] Similarly, the production location P _B and material X to search the records of the material requirements planning 1, the total required amount 6 of the material X in the production location P _B determined, held in the storage means. In total required amount 6 of the material X in the production location P _B, the required amount of time T is X _B, ordering remaining the X _ZB. In addition, the common stock common stock is 0, so the number of inventory reserve at the time to create a total required amount of material X of the production location P _B is set to 0. Thus, the net required amount X _TB of the material X at the production place P _B is _calculated as X _TB = X _B −X
Record on _RB . In addition, production place P _B
Record

Based on the net requirement X _TA of the material X at the production place P _A obtained as described above, the order quantity is rounded down in consideration of the order receiving unit of the ordering party or the ordering unit of the ordering side. as the quantity of planned order 7 Request _{X OA = X a -X R +} X SA ( increased order quantity for because X _SA fit). Material name X, period T, quantity X
_OA, by adding a production location P _A as outgoing destination, creates a purchase order planned order 7, held in the storage means. Then, an order form is output based on the planned order and the order is placed.

Similarly, based on the net requirement X _TB of the material X at the production place P _B , the order quantity is rounded down in consideration of the order unit of the supplier, and X _OB = X _B −X _RB Obtain + X _SB (X _{SB is} the order quantity increased due to rounding). And
Material name X, period T, quantity X _OB ,
By adding a production location P _B as outgoing destination, the order will order 8
Create

In consideration of the lead time (the number of days from the time the material is ordered until the material is delivered), the material is delivered to the supplier so that the material is delivered like the planned order 7 and the planned order 8. To order. As a result, during the period T, the material X having the material name X, the delivery destination P _A , and the quantity X _OA is delivered 7 ′.
Material X, material name X, period T, delivery destination P _B ,
Since the material X having the quantity X _OB of the material X as the delivery information 7 'is individually packed and received, it can be supplied to the respective production locations P _A and P _B without unpacking.

FIG. 2 shows a second embodiment of the present invention.

Hereinafter, a case where the material is a part will be described as an example.

FIG. 2A shows a file configuration according to the embodiment of the present invention. In FIG. 2A, reference numeral 21 denotes an item file, which is a file that holds item-specific information such as an item number and an item name. Reference numeral 22 denotes a product configuration file, which is a file for holding child part information (basic unit, defective rate, etc.) necessary for creating a higher-level item for the item. Reference numeral 23 denotes a stock file, which is a file for holding information on a place where items are stored and a quantity.

Reference numeral 24 denotes a purchase / outsourcing file, which is a file for holding information on purchase conditions for outsourced products, purchased items, and the like with external business partners. Reference numeral 25 denotes a net change file, which is a file for holding information on addition and change of a production plan. Reference numeral 26 denotes a calendar file which holds a table in which calendar dates are associated with factory dates (serial numbers excluding holidays).

Reference numeral 27 denotes an order order file, which holds information on a production plan from a product to a part, such as a confirmed production instruction, a planned production instruction, an order remaining, and an order plan. Reference numeral 28 denotes a requirement file, which is a file for holding the production requirement of the upper item and the requirement of the lower part required for the production requirement of the upper item.

Reference numeral 29 denotes a material requirement planning means which supports a material planning by using a computer and a computer program.

In the configuration shown in FIG. 2A, the item 21 and the product structure 22 have a hierarchical relationship, and the item 21 is in the upper hierarchy, the parts information group constituting the upper item, and the upper item using the same lower item. There is a hierarchical relationship for group information. The item 21 and the stock 23 have a hierarchical relationship, and the item 21 is in a higher hierarchy, and has a hierarchical relationship with respect to the stock information for each stock location of the item. The item 21 and the required amount 28 have a hierarchical relationship, and the item 21 is a higher hierarchy, and has a hierarchical relationship with respect to the required amount information for each item.

The item 21 and the order file 27 have a hierarchical relationship, the item 21 is a higher hierarchy, and there is a hierarchical relationship with respect to the information on the arrangement status by item. Item 21 and purchase
Outsourcing 24 has a hierarchical relationship, and the item is a higher hierarchy,
There is a hierarchical relationship between items and purchase subcontract information (unit price, production lead time, etc.).

FIG. 2B shows a component configuration of the component X. 3
Reference numeral 1 denotes a screw component in which a seal printed with the word “front” is attached to the head of the screw A. 32 is a screw A,
Outsourced parts. Reference numeral 33 denotes a sticker “A” on which the character “Previous” is printed. Reference numeral 34 denotes a raw material member D, which is a raw material member for manufacturing the screw A. Reference numeral 35 denotes a hierarchical structure of the part X. A seal “a” and a screw A are provided below the layer of the part X, and a raw material member D is provided below the screw A.

FIG. 2C shows the component configuration of the component Y. 4
Reference numeral 1 denotes a screw component in which a seal printed with the word “rear” is attached to the head of the screw A. 32 is a screw A, which is an outsourced part. Reference numeral 43 denotes a sticker “b” on which characters “back” are printed. Reference numeral 34 denotes a raw material member D, which is a raw material member for manufacturing the screw A. 45 is a part Y, a screw A,
The seal “b” shows the hierarchical structure of the raw material member D.

FIG. 3 shows a second embodiment of the present invention and shows examples of the contents of a net change file, a product configuration file, an item file, and a purchase / outsourcing file.

FIG. 3A shows the contents of the net change file, where X represents a screw X, Y represents a screw Y, and A represents a screw A (the same applies hereinafter). A represents a “front” seal, B represents a “rear” seal, and D represents a raw material member D (the same applies hereinafter). The net change file contains a higher order number for each item number (X, Y) (a product has a production number for each production lot), a start date (production start date),
It has delivery dates, quantities, and production locations (manufacturing lines (L1, L2) using parts such as screws X and Y).

FIG. 3B shows the contents of the product configuration file, which has a lower part (child item number), a basic unit, a defect rate, and a supply category of a hierarchical structure for each item number (parent item number). .

FIG. 3 (c) shows the contents of the item file, including inventory, lead time (LT), yield, LC (low level code), product category (internal production, purchase, etc.), item number for each item number. The place (production place) where the item is used is provided as information. LT (lead time) is the number of days required to manufacture and arrange an item. LC (low level code) indicates the deepest part hierarchy level. In addition, the item file holds, as units when ordering parts, a lot grouping unit for ordering the order quantity for a plurality of periods at once, and a rounding unit for rounding the quantity assembled for each lot to the order unit. .

FIG. 3 (d) shows a purchase / outsourcing file, in which the purchase / outsourcing destination, unit price,
Manufacturing unit (holds the unit of order when uniting the ordered quantity into a lot unit and the unit amount of ordering the component quantity. For example, it defines and holds the unit of the rounding of the lot and the order quantity of the ordered part. The purchase / outsourcing file holds a lead time (LT) indicating the number of days from ordering an item to delivery.

FIG. 4 shows a second embodiment of the present invention, showing examples of the contents of a calendar file, an inventory file, an order file, and a required quantity file.

FIG. 4A shows the contents of the calendar file, which is a serial number excluding holidays with the first day of the factory day (August 22) as the starting date (hereinafter, the factory day is referred to as the factory date). Term). The calendar is referred to for calculating the delivery date of the order to be ordered.

FIG. 4B shows the contents of the inventory file, which indicates the inventory storage location for each item number. In FIG. 4B, the storage location L2 of the screw A of the item number A (L2 is the screw A
Represents a production place (line) used for assembling), and that there is 100 common stocks of the screw A.

FIG. 4 (c) shows the contents of the order file. The number of each order number (A01 represents the order number of the threaded part A), the delivery date, and the production place (L1) using the order scheduled to be ordered. Is held.

FIG. 4D shows the contents of the required quantity file, which represents the required quantity corresponding to the high-order item for each item number, and includes the high-order number (order number of the high-order part),
It holds the number, delivery date, and delivery destination. In the case of FIG.
The order number A01 is assigned to the screw A, which is the upper part of the product number D (raw material member D), and the delivery date is 1,1,100 pieces.

The operation (1) of the second embodiment of the present invention will be described with reference to FIGS. The operation (1) according to the second embodiment of the present invention is a process of calculating the total required amount of the screw A at the production location (delivery destination) L1 from the net change of the part X caused by the change of the production plan of the production location L1. It is. FIG. 5 is an explanatory diagram of an initial setting for calculating a required amount of related parts when a production plan of a product is changed.

(1) Initial setting For example, it is assumed that a production plan is changed at the production place (line L1), and that the required quantity of the part X is changed (the change of the production plan is recorded in the net change file 25). You.
At this time, based on the required quantity of the part X, the lower component of the part X is referred to a file (net change file, item file, product configuration file) to calculate the required quantity of the lower component, and the required quantity record is obtained. To record.

FIG. 5A shows the relationship between the component X and the component at the next lower level. FIG. 5B shows a required quantity record of the part X. Numeral 60 denotes a required quantity record, which is the content of the net change file for the part (seal "A", screw A) at the next lower level of the part X. Product number, higher order number, delivery date, quantity, and delivery destination (production location) are expanded in the required quantity record based on the requirement record, and the delivery destination (production location (L1) using screw A) is recorded as the product location. It is.

FIG. 5C shows the relationship between the component Y and the component at the next lower level. In FIG. 5D, reference numeral 61 denotes a required amount record, which is stored in the required amount record based on the contents of the net change file for the component (seal "B", screw A) at the next lower level of the component Y. The item number, the higher order number, the delivery date, the quantity, and the delivery destination are developed, and the delivery destination (the production location (L1) using the screw A) is recorded as the product location.

(2) Extraction FIG. 6 is an explanatory diagram of the operation (1) according to the second embodiment of the present invention. Reference numeral 71 denotes an item record of the item file, which has inventory of item number A, lead time (LT), yield, level code (LC), and manufacturing category. Reference numeral 72 denotes a required quantity record, which is an upper order number X0 of the item number A.
1 indicates that 100 pieces were allocated from the common stock.

The required quantities created at the time of completion by the initial setting are item A, item A and item B. From among these, the item file 21 is referred to, and attention is paid to the item having the lowest LC (low level code), and the material requirement planning is performed for the item of interest. Referring to the item file 21 and finding the shallowest LC, the item number A (LC
= 2). Therefore, the required amount record 72 of the item number A in FIG. 6 is extracted from the required amount record 60 in FIG.

(3) Requirement Planning (Overall) Next, as shown in FIG. 6, the item numbers A are arranged in order of delivery date, and for the required quantity records in order of delivery date, the common stock of the company (each production location) (Item record) and register it in the number of reserved inventory in the requirement record.

In FIG. 6, reference numeral 71 denotes an item record, which is a record of an item A (screw A) in an item file, and includes an item number, inventory, LT (lead time), yield, LC (level code), and manufacturing category (LC). Outsourcing). FIG. 6 shows the stock 100 of the item number A as the item number A.
This shows a case where the required amount of the lot with the serial number X01 of (screw A) is allocated (the stock amount is obtained by referring to the stock file 23).

In FIG. 6, reference numeral 72 denotes a required quantity record, which is a record of the required quantity obtained for each higher order number of each production location, and holds information on the production location as a delivery destination. For example, the higher order number X01 of the item number A (screw A) is the delivery date 2 (factory date), the quantity is 1,000 pieces,
Delivery destination L1). The higher order number Y01 of the item number A (screw A) is the delivery date 3, quantity 500, and delivery destination L
2, no inventory allocation (both allocation from common inventory and allocation of production location inventory are zero).

FIG. 7 is an explanatory diagram of the operation (1) according to the second embodiment of the present invention. In FIG. 7, reference numeral 72 denotes a required amount record. Reference numeral 76 denotes a material requirement planning table (1), which is a table for planning an order to be ordered for the screw A. Reference numeral 77 denotes a required amount record, which is a record of the required amount of the raw material member D created based on the scheduled order of the screw A. Reference numeral 78 denotes a material requirement planning table (2), which is a table for calculating a planned order for the raw material member D.

(4) Planning of Required Requirement by Production Location (Part 1) The total requirement of the screw A at the production location L1 is obtained.

Read the required quantity head record of item A in order of delivery date. Since the required quantity record 72 of the item number A and the higher order number X01 is the quantity of 1,000 and the number of stocks allocated is 100, the quantity after stock allocation (1,000-100 = 900)
Is added to the total requirement on the relevant factory day (period). The subsequent required record is read, and a record having the same delivery destination L1 as the leading required record is processed. The quantity of the required requirement record after stock allocation is added to the quantity of the required quantity in the corresponding period (factory date). Further, a processed mark is given to the requirement record in which the allocated quantity of the requirement record is registered in the total requirement.

In FIG. 7, the required quantity record 72 indicates that the processed record (production place L1) has been recorded from “not yet” to “done”. With regard to the required amount of delivery date 2, 900 required screws A (serial number X0
1) is determined, and a material requirement planning table for screw A (1) 7
Record on Delivery date 2 for total requirement of 6. Further, the required amount of 2,000 screws A (serial number X02) is recorded in the delivery date 3 of the total required amount in the material requirement planning table (1) 76 of the screw A.

The order remaining of item A is grasped. That is, from the order file 27, the production place is L1, the order number is A01, the quantity is 1,100 pieces, and the delivery date is period 2 (factory day 2).
Is obtained and the required quantity is stored in the remaining order of the material requirement planning table (1) 76.

The available stock is calculated. Unavailable stock is available stock (N) = available stock (N-1) +
Obtained by remaining order minus total requirement (N). If the result is a positive number, the result is unusable stock, otherwise it is zero. Data required for calculation is obtained by referring to an inventory file, an order file, and the like, and is stored in a calculation table that holds items required for calculation.

The net required amount is calculated, and when the above calculation result is a negative value, its absolute value is used as the net required amount. If it is positive, the net requirement is zero.

The lot is put together and the arrangement is changed. For in-house parts (parts that are manufactured and delivered only in-house), the item file contains a lot
The rounding unit of the order quantity is recorded, so refer to it. For parts purchased and outsourced from outside, the lot combination method and rounding unit are recorded in the purchase / outsourcing file, so refer to them. The net requirement is put together in a lot by the lot putting method, and the fraction is adjusted to the order unit in a rounding unit to set the order quantity (for example, when the order unit is 500 pieces, the net requirement is 700 pieces. 1,000). The lot summarizing method is for summarizing the required amount for a continuous period. For example, the two-period summarization method summarizes the net requirements for two periods into one net requirement. If the net requirement for period two is 300 and the net requirement for period three is 400, the two requirements are combined. To a total of 700 pieces, round the order unit, and set the order
Order with 00 pieces. FIG. 7 after performing the above processing.
A material requirement planning table (1) 76 (table group on the memory) is created. The obtained net required quantity and the order to be ordered are stored in the material requirement planning table (1) 76 in order to determine the required quantity of the part one level lower. The order to be ordered is stored in the order file together with the item name, delivery date, quantity, production place, and the like as necessary.

Further, the parts of the lower layer of the screw A are expanded in one stage (the same processing is performed for the parts of the parts layer of the lower one level), and the lower parts of the screw A are referred to by referring to the product configuration file. , And the required quantity of lower-level components is calculated. In the case of the second embodiment, since the lower layer of the screw A is the raw material member D using the parts table, the same processing as described above is performed on the raw material member D. At this time, the required amount of the raw material member D is calculated from the scheduled order of the screw A, and the same calculation as described above is performed on the material requirement planning table (2) 78 to obtain the planned order of the raw material member D. Ask. In this process, for the required amount of the raw material member D, the delivery destination when the raw material member D is received is set to L1 where the screw A is produced.

In FIG. 7, reference numeral 77 denotes the contents of a required amount record obtained as a result of one-step development of the raw material part D after the processing for the screw A is completed. At this time, the planned order of the screw A (actual order quantity) is delivery date 3, quantity 2,0.
00, and the delivery destination L1, the product number D, the higher order number A02, the delivery date (period) 2 (the raw material member) based on the scheduled order of the screw A remaining in the material requirement planning table (1) 76. Lead time LT of screw X above D
, The delivery date of the raw material is assumed to be 2), and the delivery destination L1
The required amount record 77 of the raw material member D having the following is created. Similarly, according to the unordered order number A01 of the screw A, the required amount record 77 of the raw material member D corresponding to the unordered order number A01 is created. Further, if necessary, the lot is assembled and the arrangement is changed, and the order to be ordered for the raw material D is obtained.

The above-described processing is performed to obtain an order to be ordered for the raw material member D, and place an order. Then, the raw material member D is sent to the manufacturer of the screw A in the delivery date 2, and 2,000 screws A are delivered in the delivery date 3. At this time, since the delivery destination L1 is recorded in the received package, the package can be sent to the production place L1 in a packed state without opening the package.
Further, when the raw material member D is delivered in the delivery date 2, the raw material member D is attached to the delivery date 2 and a production order is made to the screw A manufacturing company in accordance with the order plan of the screw A. As a result, in the delivery date 3, 2,000 screws A are delivered at the delivery destination L1.

For the raw material member D for which the unordered order number A01 has been obtained as the required amount, if the actual order has already been placed, no new raw material member D will be ordered. Place an order in the same manner as above.

FIG. 8 shows the operation (2) of the second embodiment of the present invention.
FIG. FIG. 8 shows a process for planning the total required amount of the screw A from the part Y in the production place L2.

In order to obtain the required plan of the screw A at the production place L2, the required record 72 of the production plan at each production place (see FIG. 6) is searched for the product A and the production place L2. In the found required amount record, the record of “processing” is changed from “not yet” to “completed” as shown in the required amount record 72 of FIG. Then, the total required amount of the screw A is calculated in consideration of the stock, and is recorded in the total required amount of the material requirement planning table (1) 83 of the screw A at the production location L2 in FIG. The result of the total requirement planning of the screw A is that the quantity of the delivery date 3 of the total requirement is 500 pieces (production number Y01), the quantity of the delivery date 5 of the total requirement is 500 pieces (production number Y02), and the delivery date of the total requirement. The quantity of 6 is 500 pieces (production Y03).

The order remaining of the item A whose production place is L2 is grasped. It is confirmed from the order file whether there is an order remaining for the production location L2. It does not exist in the operation (2) of the second embodiment.

The available stock is calculated. Unavailable stock is available stock (N) = available stock (N-1) +
Obtained by remaining order minus total requirement (N). In the case of the present embodiment, the available inventory is 100. If the result is a positive number, the result is considered unusable stock, and zero otherwise.

The net required amount is calculated, and when the above calculation result is a negative value, the absolute value of the result is used as the net required amount. If positive, set the net requirement to zero. In the case of this embodiment, the number is 400 in period 3, 500 in period 5, and 500 in period 6.

[0086] The arrangement is changed. That is, the net required quantity is put together in a lot by the lot putting method, and the number of orders is set by adjusting the fraction to the order unit in the rounding unit. 2
As a period consolidation method, the order quantity for period 3 is rounded to 50
Make it zero. The order number is A03. Similarly period 5
And the net amount in period 6 is rounded to 1,0
00 and the order number is A04.

Further, the lower required quantity is developed in one stage. With reference to the component file, it is determined that the lower layer of the screw A is the raw material member D, and a required amount of the raw material member D is created. The same processing as above is performed based on the order to order the screw A. That is, in the required amount planning of the raw material member D, the required amount of the raw material member D is set to the delivery date and the quantity of 500 pieces (the size of the raw material member D for 500 screw A) in accordance with the order to be ordered with the order number 03 of the screw A, The delivery destination is L2 and the higher order number is A03. Further, in accordance with the scheduled order of the order number 04 of the screw A, the required amount of the raw material member D is set to the delivery date 4, quantity 1,000 (the size of the raw material member D for 1,000 screws A), delivery destination L2, higher order. Number A04.

As described above, in accordance with the required amount record 84 of the raw material member D, the predetermined amount of each raw material member is delivered to the delivery destination L2 at the delivery date 2 and the delivery date 4. Then, the raw material members are sent to the screw manufacturing company, and the screws A are delivered to the production location L2 in accordance with the scheduled order of each screw A.

FIG. 9 is a diagram showing a flowchart of the second embodiment of the present invention.

In FIG. 9, in S1 as an initial setting, required quantity development of lower parts is performed based on the production plan, and a required quantity record is generated. Then, the production location of the production plan is recorded in the required quantity record as the destination of the required quantity. In S2, a component one level lower (the component of the first level code 2) is extracted. In S3, it is determined whether or not the processing is to be terminated. If all the extraction of the items created from the required amount has been completed, the processing is terminated. If unprocessed data remains, the process of S4 is performed. From the unprocessed requirements related to the extracted items, the same requirements at the delivery destination are read out to make a requirements plan.

At S5, the net required amount is obtained. At S6, lots are put together. The arrangement is changed in S7. In S8, if the processing of all the required quantities of the extracted item (A) has not been completed, a required quantity plan is made again for the required quantities of the other delivery destinations. S
In step 9, it is determined whether there is an unprocessed required amount in the item. If there is no processing, the processing after S4 is repeated. If there is no outstanding
In S10, one stage lower development is performed. That is, one-step lower-level development of the parts table is performed based on the ordering plan (order) created for each delivery destination. The production location of the ordered parts is also recorded as the delivery destination in the required quantity of the lower order item. Therefore, the processing after S2 is repeated.

(Appendix 1) Required amount holding means for recording and holding the required amount of the material together with the material name and the name of the place where the material is used, and searching for the required amount holding means by the material name and the place name, A material management apparatus characterized in that a required quantity is obtained for each place name, an order is planned, and material order information is created for each place name.

(Supplementary Note 2) The required amount of the material is obtained in consideration of the stock amount of the material and the remaining order of the same material in the past at the same place of use, and an order is planned based on the required amount. 2. The material management apparatus according to claim 1, wherein the order management information is created.

(Supplementary Note 3) Information on the layers of the materials constituting the materials is provided, and the material name and the required amount at the place of use are obtained for an arbitrary layer. Appendix 1 characterized in that an order is planned for the location and material ordering information is created for each place name.
Or the material management device according to 2.

(Supplementary Note 4) There is provided a required amount holding means for recording and holding the required amount of the material together with the name of the material and the name of the place where the material is used. The required quantity is calculated based on the name and the place name, and the order is planned.
A material management method, wherein material ordering information is created for each place name.

(Supplementary Note 5) There is provided a required amount holding means for recording and holding the required amount of the material together with the name of the material and the name of the place where the material is used. The required quantity is calculated based on the name and the place name, and the order is planned.
A storage medium that stores a computer program for creating material ordering information for each place name.

(Supplementary note 6) Supplementary notes 1, 2 or 3 characterized in that a plurality of processes of materials are combined into a single order quantity to obtain a net required quantity, and the required quantity is rounded up to an order unit to obtain a net order quantity. 3. The material management device according to 3.

(Supplementary Note 7) Means for holding the total required amount of materials in accordance with the period, remaining order to be received in each period, available inventory in each period, remaining order, available stock, and total required amount And means for obtaining and holding the net required quantity based on the data, and means for obtaining and holding the order to be ordered by performing lot summarization or rounding processing on the net required quantity. Create order information,
The material management apparatus according to any one of supplementary notes 1, 2, 3, and 6, wherein the material management apparatus outputs the information.

(Supplementary Note 8) An item file that holds item-specific information such as an item number and an item name, a product configuration file that holds a product configuration, a stock file that holds inventory information, and purchase with an external supplier Purchasing / outsourcing file that holds information on conditions, net change file that holds information on adding and changing production plans, calendar file that holds calendar dates as serial numbers excluding factory holidays, and holds information on production plans Appendices 1, 2, 3, 6 and 7 characterized in that it has an order file and a requirements file which holds the production requirements of the higher-level items and the lower-level parts required for the production requirements of the higher-level items. Material management device as described.

(Supplementary Note 9) The total required amount of the material is obtained and held in correspondence with the period, the remaining order to be received for each period is obtained and held, and the available stock for each period is obtained and held, and the order is placed. Net requirements are obtained and retained based on the remaining, available inventory and total requirements, order planning orders that have been rounded or consolidated for the net requirements are retained, and order information is created and output. 4. The material management method described in Supplementary Note 4.

[0101]

According to the present invention, it is possible to supply a packed product to each production place without opening the package. This eliminates the need for the cumbersome work of unpacking the delivered product, distributing it to the number required at each production site, and supplying it to each production site, as was conventionally done. Therefore, the labor for managing the delivered products can be significantly reduced.

Further, material management can be performed for each production location with the same item number without increasing the item number. Therefore, material management for each production location can be performed without increasing the amount of documents required for material management.

[Brief description of the drawings]

FIG. 1 is a diagram showing a first embodiment of the present invention.

FIG. 2 is a diagram showing a second embodiment of the present invention.

FIG. 3 is a diagram showing a second embodiment of the present invention.

FIG. 4 is a diagram showing a second embodiment of the present invention.

FIG. 5 is an explanatory diagram of an operation (1) according to the second embodiment of the present invention.

FIG. 6 is an explanatory diagram of an operation (1) according to the second embodiment of the present invention.

FIG. 7 is an explanatory diagram of an operation (1) according to the second embodiment of the present invention.

FIG. 8 is an explanatory diagram of an operation (2) according to the second embodiment of the present invention.

FIG. 9 is a diagram showing a flowchart according to the second embodiment of the present invention.

FIG. 10 is an explanatory diagram of a conventional technique.

FIG. 11 is a diagram showing a flowchart of a conventional technique.

[Explanation of symbols]

1: Material Requirements Planning 3: Common stock 5: total required amount of material X of the production location P _A 6: total required amount of material X of the production location P _B 7: ordering plans Order 7 ': delivery information 8: ordering schedule Order 8 ': Delivery information

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Tomoyuki Nagakawa 1Fuji-cho, Hino-shi, Tokyo FFC Co., Ltd. (72) Inventor Takashi Tomita 1006 Oojidoma, Kadoma-shi, Osaka Matsushita Electric Industrial Co., Ltd. In-house (72) Inventor Toshiaki Fujino 1006 Kazuma Kadoma, Kadoma-shi, Osaka Matsushita Electric Industrial Co., Ltd.F-term (reference) 3F022 MM07 MM22 MM28 5B049 BB07 BB11 CC05 CC27 EE00

Claims (5)

[Claims] Claims: 1. A required amount holding means for recording and holding a required amount of a material together with a material name and a name of a place where the material is used, and searching for the required amount holding means by the material name and the place name, and searching for the material name and the location. A material management apparatus, wherein a required quantity is obtained for each name, an order is planned, and material order information is created for each place name. 2. A required amount of material is determined in consideration of a stock amount of material and a remaining order of the same material in the past at the same place of use, an order is planned based on the required amount, and a material is ordered for each place name. The material management apparatus according to claim 1, wherein information is created. 3. The apparatus comprises hierarchical information of materials constituting the material,
Calculates the material name and the required amount at the place of use for an arbitrary hierarchy, obtains the material name and the required amount at the place of use for the material of the lower hierarchy, and plans the order, and creates the material ordering information for each place name The material management apparatus according to claim 1, wherein: 4. A required amount holding means for recording and holding a required amount of a material together with a material name and a name of a place where the material is used, searching the required amount holding means by the material name and the place name, and searching for the required amount of the material. A material management method comprising: obtaining a required quantity based on a place name; planning an order; and creating material order information for each place name. 5. A required amount holding means for recording and holding a required amount of a material together with a material name and a name of a place where the material is used, searching the required amount holding means by the material name and the place name, and searching for the required amount of the material. A storage medium storing a computer program for obtaining a required quantity based on a place name, planning an order, and creating material order information for each place name.