JP2003167615A - Production plan making device and method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a device and a method for making a production plan capable of much more precisely estimating staff labor costs. <P>SOLUTION: The operating time of tacts and factories necessary for the production of the prescribed number of products is calculated, and production capability is calculated from the change of the tacts in that month and the tacts in the next month by using production capability data indicating the relation of the tact change and production capability, and the necessary number of staffs is calculated by considering the production capability. Thus, it is possible to much more precisely calculate staff labor costs by using the number of staffs necessary for production, a staff labor unit price set for each staff, and the operating time. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production planning apparatus and method. In particular, the present invention relates to a production plan planning apparatus and method useful for formulating an optimum production plan when a tact change occurs in production planning.

[0002]

2. Description of the Related Art For example, Japanese Unexamined Patent Publication No. 2001-27905 discloses a production plan creating method for formulating a feasible plan for demand based on equipment production capacity, parts inventory quantity, and delivery quantity.

Further, Japanese Patent Laid-Open No. 7-282149 discloses that
Parts inventory, delivery, production required to meet demand,
Disclosed is a production planning system that formulates an executable production plan in consideration of lead time.

[0004]

In the conventional production planning method, a feasible plan was prepared based only on the production facility capacity, parts inventory, and the like. By the way, in order to make a more optimal production plan, it is important to consider not only the production facility capacity, but also the cost required for personnel as resources, but in the past, a method for estimating the personnel cost more accurately Was not suggested.

Therefore, an object of the present invention is to provide a production plan planning apparatus and method which can contribute to more optimal production planning by providing a method for estimating the personnel cost more accurately.

[0006]

That is, according to the present invention, in a production plan planning apparatus for planning the production plan number of products in the production process, the tact time and the operating time of the production process required to produce a predetermined production number. Based on the current takt and the calculated tact before the production plan quantity planning, using the means for calculating the tact change, and the production efficiency change data showing the relationship between the tact change and the production efficiency, It is provided with means for calculating the production efficiency in the calculated tact change, and means for calculating the number of personnel required to produce the predetermined production number using the production efficiency.

According to this, it is possible to calculate the number of personnel necessary for producing a predetermined number of units in consideration of the change in production efficiency according to the change in tact.

Further, according to the present invention, in the production planning apparatus, based on the calculated number of personnel, the personnel unit price set for each personnel, and the calculated operating time,
A means for calculating the personnel cost may be further provided.

Further, according to the present invention, in the production planning method for planning the production planned number of products in the production process, the step of calculating the tact time required to produce a predetermined production number and the operating time of the production process, Based on the current tact and the calculated tact before planning the production plan, using the process of calculating the tact change and the production efficiency change data showing the relationship between the tact change and the production efficiency, the calculated tact change And a step of calculating the number of personnel required to produce the predetermined number of units, using the production efficiency.

According to the present invention, in the production planning method, based on the calculated number of personnel, the personnel unit price set for each personnel, and the calculated operating time,
You may further provide the process of calculating a personnel cost.

Further, according to the present invention, in the production planning apparatus for planning the production planned number of products in the production process, the tact time and the operating time of the production process required for producing the predetermined production number by the predetermined number of personnel are set. Based on the means for calculating, the current tact and the calculated tact before the production plan quantity planning, using the means for calculating the tact change, and the production efficiency change data showing the relationship between the tact change and the production efficiency, A means for calculating the production efficiency in the calculated tact change, and a means for using the production efficiency to recalculate the operating time required to produce the predetermined production quantity by the predetermined number of personnel. .

The production planning apparatus of the present invention further comprises means for calculating a personnel cost based on the predetermined number of personnel, the personnel unit price set for each personnel and the recalculated operating time. You may prepare.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described through embodiments of the invention.

FIG. 1 is a block diagram showing the outline of the configuration of a production planning apparatus 10 according to an embodiment of the present invention as functional blocks, and FIG. 2 illustrates the hardware configuration of the production planning apparatus 10 of the embodiment. It is a block diagram.

The hardware configuration of the production planning apparatus 10 is a general-purpose computer mainly composed of a CPU 42 as a central processing unit.
The bus 44 connected to the CPU 42 has a cache memory 46 and its cache controller 48, a main memory 50, a graphics controller 52 to which a CRT 54 is connected, a keyboard interface 56 to which a keyboard 58 and a mouse 60 are connected, a hard disk 64 and a floppy disk. An input / output interface 62 to which a (registered trademark) disk 66 is connected is connected.

As blocks, a data storage unit 22 for storing various data in each process, and a data input unit 2 for inputting the actual inventory value of each process and the sales plan of the sales process.
4, an index calculator 26 that calculates a profit index based on orders, orders, deliveries, shipments of each process and costs associated with production of each process, and an input inventory actual value, sales plan, and inventory target value. The order planning, ordering, delivery, and shipping of each process based on the plan planning unit 28, and the order storage range data stored in the data storage unit 22 is set. A range setting unit 30, a plan determination changing unit 32 that determines the feasibility of the basic plan based on the orderable range set for each process and changes the plan so that it can be implemented, and the planned basic plan and the changed plan. A plan output unit 34 that outputs a plan, a plan determination, a plan profit index, and the like
And a basic plan created by the planning unit 28 (for example,
Calculate the operating time of the tact and production equipment from the planned production quantity), use the tact data described below to determine whether the basic plan is feasible, and change the basic plan as necessary. The department 70, a personnel planning unit 72 that determines the required number of personnel from the tact and efficiency data described later, determines whether the basic plan is feasible, and changes the basic plan as necessary, the number of personnel, and operating time. And a personnel cost calculation unit 74 for obtaining the personnel cost from the personnel data.

Each functional unit of the production planning apparatus 10 of such an embodiment is realized by integrating the hardware configuration illustrated in FIG. 2 described above and the software described below. The function of each functional unit will be described in detail below, including the correspondence with the hardware configuration.

The data storage unit 22 corresponds to an external storage device such as a hard disk 64 as a hardware configuration. In the data storage unit 22, the cost required from the delivery of the product or part in each process to the shipping of the product, for example, material cost, labor cost, equipment cost, inventory storage cost per product or part Process data including data related to time and data such as time required to produce a product or part, storage time, etc., transportation data related to shipping costs and transportation time associated with shipping products or parts, inventory as inventory target for each process Target value data, equipment capacity in each process to set the orderable range of each process (specifically, operation data related to equipment operation such as maximum operating time of equipment) and personnel composition (specifically, personnel) Unit price or personnel data regarding personnel such as the number of employees), order range data regarding operating range, sales data such as the selling price of each product, maximum tact time, etc. Tact data about the tact,
The efficiency data regarding the production efficiency with respect to the tact change, the production plan data regarding the planned plan or the past plan, and the like are stored.

The index calculation unit 26 has a hardware configuration as follows.
The CPU 42 that executes the processing program, the main memory 50 that stores the program, and the like correspond to this. Index calculator 2
6 is based on data relating to orders, orders, deliveries, and shipments set for each process when requested by the plan making unit 28 and the plan judgment changing unit 32, and process data and transportation data stored in the data storage unit 22. Then, the profit index is calculated, and the calculated profit index is returned to each requested part. The return on total capital (ROA =
(Revenue-expenditure) / asset), or an index obtained as the product of profit-producing power and profit-producing speed (S
-ROA = (sales-production input material cost-operation cost) / stock material cost) can be defined and used. Further, other profit indicators may be defined and used.

The plan making unit 28 has a hardware configuration as follows.
The CPU 42 that executes the processing program, the main memory 50 that stores the program, and the like correspond to this. Planning Department 2
Reference numeral 8 denotes a basic plan, that is, an order for each process, based on a processing program described later based on the actual inventory value input by the data input unit 24, the sales plan, and the inventory target value data stored in the data storage unit 22. Set orders, deliveries, and shipments. The processing operation will be described later.

The order acceptable range setting unit 30 has, as a hardware configuration, a CPU 42 for executing a processing program, a main memory 50 for storing the program, and the like. The orderable range setting unit 30 sets the orderable range of each process based on the order range data stored in the data storage unit 22 regarding the facility capacity, the personnel composition, the operable range, and the like in each process. The orderable range is a range set by the production amount obtained as the lower limit value or near the lower limit value of the steady process of each process and the production amount obtained as the upper limit value or near the upper limit value of the steady process. The lower limit of the regular processing is, for example, the production amount per month when the production line speed is set to the slowest and normal operation days are used, and the personnel required for that speed are allocated and holiday operations and overtime operations are not performed. Alternatively, it can be obtained as a production amount slightly larger than this production amount. In addition, the upper limit of the routine processing is, for example, the maximum of the production line speed and the personnel required for that speed are assigned, and the maximum value of the holiday operation and overtime operation is the maximum value of one month. It can be calculated as the production amount or a production amount slightly smaller than this production amount.

The plan determination changing unit 32 also corresponds to the CPU 42 for executing the processing program, the main memory 50 for storing the program, and the like as the hardware configuration. The plan determination changing unit 32 determines whether the processing capacity of each process is excessive or insufficient based on the comparison between the orderable range set for each process by the orderable range setting unit 30 and the basic plan created by the plan planning unit 28. Or change the excess or deficiency of the basic plan and the processing capacity of each process into a feasible plan by changing the time of orders, changes between processes, and changes in the initial stock value.

The data input unit 24 corresponds to a keyboard interface 56, a keyboard 58, and a mouse 60 as a hardware configuration, and the plan output unit 34 has a hardware configuration such as a graphics controller 52 and a CRT 5.
4 corresponds.

The tact operation time planning unit 70 also has a hardware configuration corresponding to the CPU 42 for executing the processing program, the main memory 50 for storing the program, and the like. The tact operation time planning unit 70 calculates the tact and the operation time within the respective upper and lower limits stored in the tact data and the operation data from the production amount from the plan preparation unit 28 and the plan determination change unit, and If neither the upper limit nor the lower limit is reached, the plan determination change unit is notified that the order is not within the orderable range. The personnel planning unit 72 obtains the required number of personnel from the tact and the efficiency data, determines whether it is feasible from the personnel data, and when it is not possible, notifies the plan determination unit that the order is not within the orderable range. To do.

The personnel planning unit 72 also has a hardware configuration,
The CPU 42 that executes the processing program, the main memory 50 that stores the program, and the like correspond to this.

The personnel cost calculation unit 74 also corresponds to the CPU 42 for executing the processing program, the main memory 50 for storing the program, and the like as a hardware configuration. The personnel cost calculation unit 74 obtains the personnel cost from the number of personnel, the operating time obtained by the tact operation time planning unit 70, and the personnel data, and outputs it to the index calculation unit, the planning unit, and the plan determination changing unit.

FIG. 3 is a block diagram showing an example of a supply chain as a concrete example in which a supply and demand plan is drafted by the production plan drafting apparatus 10 of the embodiment. As shown in the figure, the supply chain of the specific example is a sales process 102, 10 as two sales outlets that sell products A, B, C, D respectively.
4 and a part of the products A, B, C, D, and a part of the produced products A, B, C, D are two sales processes 10
The product production process 112, 114 as a product production factory for shipping to the product 2, 104 and a part of the parts a, b, c, d for producing the products A, B, C, D.
Parts supply process 1 as a parts supply company that ships to 114
26 and 128. The alphabets in parentheses in each process represent products or parts, and the arrows between the processes indicate how the products are shipped according to the order.

FIG. 4 is a flow chart showing an example of a production planning process routine executed by the production planning device 10 of the embodiment. In this routine, the production plan is created as a monthly plan. When this routine is executed, the CPU 42 of the production planning apparatus 10 of the embodiment first executes a process of inputting the inventory record of each process (S1).
0). After the input process of the inventory record of each process is performed, the process of inputting the sales plan of the sales processes 102 and 104 for one month is executed (S20).

Next, a process for calculating the orderable range of the product production processes 112 and 114 is performed (S30). The manufacturable range is calculated for each manufacturing process based on the order range data stored in the data storage unit 22 as described above regarding the facility capacity, personnel composition, operable range, etc. in each manufacturing process.

Then, processing for initially distributing the order quantity of each product from each of the sales processes 102 and 104 is performed (S4).
0). The initial distribution is performed for products A and B by proportionally distributing them to each product production process at the upper limit of the orderable range of each product production process. All the products C are ordered from the product manufacturing process 112, and all the products D are ordered from the product manufacturing process 114.

Next, the personnel cost in each production process is calculated from the order quantity (production amount) set for each production process. This processing is performed by the personnel cost calculation routine illustrated in FIG. 5 (S50).

Now, let us move to FIG. 5 for explaining the personnel cost calculation routine. In the personnel cost calculation routine, first,
From the order quantity (production quantity) set for each production process and the operation time preset as an initial value as operation data in each production process, tact = (operation time / production quantity) * C
The tact is calculated using the equation shown in (S10
0). In addition, C is a coefficient of a predetermined value. Normally, 1 is used as C, but C can be set appropriately according to the actual conditions of each production process.

Next, it is determined whether the tact calculated from the above equation is within the tact allowable range between the upper limit (fastest production rate) and the lower limit (slowest production rate) (S110).
If the tact is not within the tact allowable range, the operating time is increased or decreased so as to enter the tact allowable range (S120). As a result of increasing / decreasing the operating time, it is determined whether the tact is within the tact allowable range, and whether the operating time is within the maximum operating time (S130). When the tact is outside the tact allowable range, or When the time exceeds the maximum operation time, it is notified that the order is not within the range (S140).
If the tact and the operating time are within the allowable range, the tact calculation process (S100) is performed again.

On the other hand, when it is determined that the tact is within the tact allowable range (S110), the number of personnel required for each production process is calculated (S150). Normally, the number of man-hours required to produce one unit (unit: person * hour) is given by the product / process, so it is indicated by the number of man-hours required to produce one unit / tact. It is calculated using an expression. As a relatively highly accurate value, the actual tact * the number of personnel at that time (the actual number of personnel) may be used as the numerator.

Normally, the tact does not change within one month, so the above formula may be used to calculate the number of personnel. However, in the plan, for example, when the tact of June and July change, the worker cannot immediately become accustomed to the tact of July, and the production efficiency falls. The relationship between the change in tact and the production efficiency has the relationship shown in FIG. The tact change rate on the horizontal axis of FIG. 6 is calculated by, for example, (tact of next month−tact of this month) / tact of this month * 100. When the tact change rate is zero, that is, when the tact does not change, the production efficiency is 100%.
However, when there is a change in the tact (when the tact change rate is + or −), the worker is not accustomed to the new tact, and the production efficiency is reduced to less than 100%. Therefore, when calculating the number of personnel, it is preferable to assume such a case and use an equation represented by the number of personnel = (artificial / tact required to produce one unit) / efficiency.

When the number of personnel is calculated, it is determined whether the calculated number of personnel is within the number of personnel actually held (S160). When the calculated number of personnel exceeds the number of personnel possessed, the tact lower limit is set as a limit and the tact is lowered (S170), and the operating time to obtain the same production amount is calculated again (S180). Subsequently, it is determined whether the tact is equal to or more than the tact lower limit, and whether the recalculated operation time is within the maximum operation time (S1).
90), if the tact time and the operating time satisfy a predetermined condition, the personnel number calculation process (S150) is performed again. If the tact time or the operating time is not less than the tact lower limit and the maximum operating time cannot be satisfied, it is notified that the order is not within the order range (S140).

When it is determined that the number of personnel is within the number of personnel possessed (S160), the personnel cost is calculated for each production process (S200). The personnel cost is calculated by acquiring the personnel unit price from the personnel data and using the personnel unit price, the number of personnel, and the operating time. For example, assuming that the unit labor cost is an hourly wage per person, the personnel cost is: labor cost = personnel unit price * number of personnel *
It is calculated using the formula shown in operating time. In addition, the personnel cost is the sum of the costs set according to the contract type (regular employee, contract employee, etc.), function, type of working hours (night work, holiday work, etc.), etc.

The calculated personnel cost is output (S21
0), which will be used to evaluate the production plan.

Now, returning to FIG. 4, the production plan is evaluated based on the output value of the personnel cost (S60).
In the production plan evaluation, the profit index is calculated with the output personnel cost as one of the costs. It is determined whether or not the calculated profit index has reached a predetermined target value (S7).
0) If the profit index has reached the target value, the production plan is determined to be optimum, and the processing here is terminated. If the profit index does not reach the target value, the profit index (evaluation value)
After the order quantity (production quantity) is distributed and adjusted in the direction of increasing the cost (S80), the personnel cost calculating routine (S
In 50), the labor cost is calculated.

As described above, by calculating the personnel cost in consideration of the change in production efficiency due to the change in tact,
A more optimal production plan can be created.

In the personnel cost calculation routine of the above embodiment, the initial value is set for the operating time, but a method of setting the initial value for tact is possible without needing to describe the details.

[0042]

As is apparent from the above description, according to the present invention, a more optimal production plan can be planned by calculating the personnel cost in consideration of the change in production efficiency due to the change in tact.

[Brief description of drawings]

FIG. 1 is a configuration diagram showing an outline of a configuration of a production planning apparatus 10 according to an embodiment as a functional block.

FIG. 2 is a configuration diagram illustrating a hardware configuration of the production planning apparatus 10 of the embodiment.

FIG. 3 is a configuration diagram showing an example of a supply chain as a specific example in which a supply and demand plan is drafted by the production plan drafting apparatus 10 of the embodiment.

FIG. 4 is a flowchart showing an example of a production planning process routine executed by the production planning device 10 of the embodiment.

FIG. 5 is a flowchart showing a personnel cost calculation routine.

FIG. 6 is a graph showing the relationship between tact change and production efficiency.

[Explanation of symbols]

10 production planning device, 22 data storage unit, 24
Data input section, 26 index calculation section, 28 planning section, 3
0 orderable range setting section, 32 plan judgment changing section, 34
Plan output unit, 44 bus, 46 cache memory,
48 cache controller, 50 main memory,
52 graphics controller, 56 keyboard interface, 58 keyboard, 60 mouse, 6
2 I / O interface, 66 floppy (registered trademark) disk, 70 tact operation time planning section, 72 personnel planning section, 74 personnel cost calculating section.

Continued front page    (72) Inventor Eiji Kojima             1 Toyota Town, Toyota City, Aichi Prefecture Toyota Auto             Car Co., Ltd. (72) Inventor Toshihiro Nakamura             1 Toyota Town, Toyota City, Aichi Prefecture Toyota Auto             Car Co., Ltd. (72) Inventor Fumio Nagao             1 Toyota Town, Toyota City, Aichi Prefecture Toyota Auto             Car Co., Ltd. F-term (reference) 3C100 AA07 BB02 BB14 BB17

Claims (6)

[Claims] Claim: What is claimed is: 1. In a production planning apparatus for planning a production plan quantity of a product in a production process, a means for calculating a tact time required to produce a predetermined production quantity and an operating time of the production process, and a production plan quantity plan. Based on the previous current tact and the calculated tact, using the means for calculating the tact change and the production efficiency change data showing the relationship between the tact change and the production efficiency, the production efficiency in the calculated tact change is calculated. A production plan planning apparatus comprising: a calculating unit; and a unit that calculates the number of personnel required to produce the predetermined number of units by using the production efficiency. 2. A means for calculating a personnel cost based on the calculated number of personnel, a personnel unit price set for each personnel, and the calculated operating time is further provided. The production planning device described in. 3. A production plan planning method for planning a production plan quantity of a product in a production process, a step of calculating a tact time required to produce a predetermined production quantity and an operating time of the production process, and a production plan quantity plan. Based on the previous current tact and the calculated tact, the process of calculating the tact change and the production efficiency change data showing the relationship between the tact change and the production efficiency are used to calculate the production efficiency in the calculated tact change. A production planning method, comprising: a step of calculating; and a step of calculating the number of personnel required to produce the predetermined number of units by using the production efficiency. 4. The method according to claim 3, further comprising a step of calculating a personnel cost based on the calculated number of personnel, a personnel unit price set for each personnel, and the calculated operating time. The production planning method described in. 5. A production plan planning apparatus for planning a production plan quantity of a product in a production process, and means for calculating a tact time and a production process operation time required for producing a predetermined production quantity by a predetermined number of personnel. , The calculated tact using the means for calculating the tact change based on the current tact before the planning of the production plan and the calculated tact, and the production efficiency change data indicating the relationship between the tact change and the production efficiency. A means for calculating the production efficiency in the change, and a means for using the production efficiency to recalculate the operating time required for producing the predetermined production volume by the predetermined number of personnel, Production planning device. 6. The method according to claim 5, further comprising means for calculating a personnel cost based on the predetermined number of personnel, the personnel unit price set for each personnel, and the recalculated operating time. The production planning device described in.