JP2003173205A - Production management system, its computer program and recording medium recording program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production management system capable of swiftly carrying out delivery date calculation or the like of a product. <P>SOLUTION: The production management system is composed of a means of preparing a simple process procedure master with a unit quantity of a bottleneck process and lead time information by calculating prior and posterior lead times of the bottleneck process, preparing a resource capability master having standard operation time information of the bottleneck process, calculating a bottleneck process delivery date by subtracting a posterior lead time of the simple process procedure master from a shipment due date of an ordered product, calculating a production quantity of the bottleneck process by referring to the unit quantity of the simple process procedure master on the basis of an ordered product quantity, calculating a loading time of the bottleneck process on the basis of the production quantity of the bottleneck process and a standard operation time of the resource capability master, retrieving an idle time of a bottleneck process resource where the loading time can be added on the basis of the loading time of the bottleneck process, and fixing an ordered quantity on an ordered date when the loading time can be added to the idle time and it is judged that an order is acceptable. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to product delivery date calculation,
The present invention relates to a production management system capable of promptly calculating the required quantity of purchased products, its computer program, and a recording medium recording the program.

[0002]

2. Description of the Related Art In the MRP method, effective stock is calculated by taking a product order (order) as a demand. As a result, the necessary quantity corresponding to the stock shortage is calculated and a time packet arrangement plan is prepared. The configuration master is searched from this plan, the net requirement amount of the subordinate items is calculated, and the effective inventory is calculated for the subordinate items in the same manner to make an arrangement plan in the same manner. For this reason, it is possible to compile an order plan within the range of time packets, but make an order on the assumption that the product order does not know the linked state of the required quantity and the ordered quantity according to the bill of materials and that the resource load constraint is unlimited. A plan is made, but since the actual resources are finite, it is necessary to change the plan date if there is no margin of load, but if it is changed, it is necessary to change the plan date of the time bucket and the lower net requirement accordingly. As a result, an MRP bucket may be inconsistent and a plan that does not match the actual situation may be created.

On the other hand, the production number system is excellent in progress management because it is possible to know the association with the order and the association with the process.
Since there is no order planning and net requirement summarizing function like the RP method, the number of orders and orders will increase and it is necessary to change the tied state when changing the plan (tied change). Difficult to manage.

In the conventional production management system, when the delivery date is answered, the production management scheduling allocates the load of all the production planning orders to the resources of the process and calculates the start date and the delivery date of the production planning order, respectively. It was necessary to answer the deadline. However, when all production planning orders are assigned and the delivery date response is made, it takes a long time to access the disk due to the large number of planned orders, and the delivery date response cannot be made in a short time.

By the way, conventionally, there is a production management system that corresponds to a plan change at the time of planning a production process by calculating the load amount of only the neck process of the production process. Is not performed (see Patent Document 1). In addition, conventionally, when registering a component configuration master, based on a file in which a process procedure is registered, a retroactive date of how many days before the child component must be delivered is calculated, and the outgoing date is based on the retroactive date. Although there is a production management system that demands the demand, such a system does not focus on the neck process and calculate the delivery date of the ordered product (see Patent Document 2).

[0006]

[Patent Document 1] JP-A-5-151232 (pages 3 to 4, FIGS. 1 to 6)

[Patent Document 2] Japanese Unexamined Patent Publication No. 8-315018 (FIG. 1,
(Fig. 2)

[0007]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems of the prior art, and calculates the delivery date by creating in advance master information in which lead time information or the like focusing on the neck process is registered. It is an object of the present invention to provide a production management system capable of quickly performing the above-mentioned operations and devising a production plan suitable for the substance, a computer program thereof, and a recording medium storing the program.

[0008]

In order to achieve the above object, the present invention is, firstly, a production management system for performing computer-controlled production management of a product in which at least a neck process exists between the initial process and the final process. Then, the product quantity of the neck process (for example, neck process B) and the intermediate product (for example, intermediate product “A”) produced by the neck process (for example, neck process B) by calculating the lead time and the post process lead time centering on the neck process. A unit quantity (for example, neck process item unit quantity), means for creating a simple process procedure master (16) having both lead time information (for example, simple process procedure master creating means 100), and standard work time information for at least the neck process. Means for creating a resource capacity master (18) having (for example, resource capacity master creating means), and a planned shipping date of the ordered product (for example, Product X shipping date ○ month 9 days)
By subtracting the lead time information (for example, 1 day) after the simple process procedure master from
The unit quantity (eg, 1) of the simplified process procedure master is referred to based on the means for calculating (e.g., neck process delivery date calculation means 101) and the quantity of ordered products (eg, quantity 100 of product X). Means (eg, neck process production quantity calculation means 103) for calculating the production quantity (eg, 100) of the neck process, and load time of the neck process based on the production quantity of the neck process and the standard work time of the resource capacity master ( For example, a means for calculating (3H) (for example, load time calculating means 104) and a load time for the neck process (3
H)) a means for searching the free time of the neck process that can add the load time (for example, the free time determining means 105), and a case where the load time can be added to the free time found by the search. Is a means for deciding that the order can be accepted and determining the order quantity on the date when the order is accepted (for example, delivery date deciding means 107), and makes the computer function as each of the above means. And a recording medium having the program recorded therein. With this configuration, since the post-process lead time and the pre-process lead time centering on the neck process are registered in advance in the simple process procedure master, it is possible to quickly determine whether or not to accept an order for a product including a plurality of processes. it can.

Secondly, purchased products (for example, purchased products) of each product, unit quantity of the purchased products for the products (for example, product unit quantity 2, purchase product unit quantity 1, etc.), and lead time information of the purchased product (for example, Intermediate products from purchased to product X,
And a fixed lead time of the product is added), a means (for example, a simple purchase product creating means 109) for creating a simple purchase product master (17) is provided, and when the order quantity is confirmed, the simple purchase product is A means for calculating the required quantity (for example, 50) of the purchased product with respect to the quantity of the ordered product (for example, the quantity of the product X of 100) by referring to the unit quantity of the master (17) (for example, the purchased goods necessary quantity calculation means 111)
And a means for calculating a scheduled delivery date of the purchased product (for example, a scheduled purchase delivery date calculation means 110) with reference to the lead time information of the simple purchase product master (17). The production control system according to the first aspect, a computer program for production control for causing a computer to function as each of the above means, and a recording medium recording the program. With such a configuration, since the unit quantity of the purchased product for the product is registered in advance in the simple purchased product master, the required amount of the purchased product of the product including a plurality of steps can be quickly calculated.

In this section, reference numerals of the present embodiment are attached to correspond to the constituent elements of the present invention, but these are attached for convenience of clarifying the corresponding relationship, and the constitution of the present invention Of course, the elements are not limited to those having these codes.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below.

FIG. 1 is a diagram showing the construction of a production management system according to the present invention. Reference numeral 1 is a server computer which constitutes this system, and an input unit 2 such as a keyboard for inputting various information, a CRT, etc. Display (display unit) 3, ROM 4, RAM for storing various data
5, external memory reader 6 (image scanner, etc.), FIG.
A server program 7 and a database 8 in which the operating procedures of this system including the programs shown in 6 to 22 are stored.
Hard disk drive 9 serving as an external storage device storing the files and other client computers 10 and 11
And a LAN interface 12 for communicating with each other through a LAN, and a CPU 13 that controls the above-mentioned units based on the program 7 to execute the program.

FIG. 24 is a block diagram of the functions of the program 7 of the present invention. First, the outline of the present invention will be described based on this block diagram. It should be noted that what is shown by a broken line block in the figure is created by the operator inputting various data from the input unit 2 and registered in the database 8. Reference numeral 100 denotes a simple process procedure master creating means, which is based on the item master 13 (FIG. 4), the configuration master 14 (FIG. 5A), and the process procedure master 15 (FIG. 16) created based on the input data. Then, the simple process procedure master 16 (FIG. 7) is automatically generated. Reference numeral 109 is a simple purchase product master creating means, which automatically generates a simple purchase product master 17 (FIG. 8) based on the master data 13, 14, and 15 described above. Reference numeral 101 denotes a neck process delivery date calculating means for calculating the neck process delivery date based on the post-process lead time in the simplified process procedure master 16 and an equation (described later). Reference numeral 102 denotes a search start date calculating means for calculating the search start date of the neck process based on the preceding process lead time and the formula (described later) in the simplified process procedure master 16. 103 is a neck process production quantity calculation means,
The production quantity of the neck process is calculated based on the unit quantity of the simple process procedure master 16 and the formula (described later). Reference numeral 104 is a load time calculating means, which is the production quantity calculated by the neck process production quantity calculating means 103 and the standard work quantity, the standard work time, the standard setup time of the resource capacity master 18 (FIG. 9), and the formula (described later). ), The load time of the neck process resource is calculated. Reference numeral 108 denotes a neck process load bucket creation means, which is the calendar data of the simple process procedure master 16, the calendar CAL1, and the capacity center capacity table (RCRP specification table) 19 (FIG. 1).
0), the neck process load bucket 21a, etc. (see FIG. 1).
2) is created. A vacant time determining means 105 determines whether or not there is a vacant load time in the neck process load bucket 21a during the neck process delivery date and the search start day. Reference numeral 107 denotes a delivery date fixing means, and if it is determined by the determination means 105 that there is a free time, it is determined that the product can be ordered, and the product requirement bucket 20a (FIG. 11) is shipped. The order quantity of a product is registered in the confirmation column. 11
Reference numeral 1 denotes a purchase product requirement amount calculating means, which reads out the purchase product unit quantity for the product unit quantity from the simple purchase product master 17 and calculates the purchase product requirement quantity for the planned production quantity. 110 is a means for calculating the planned delivery date of the purchased item,
The fixed lead time of the purchased product is read from the simple purchase product master 17, and the scheduled delivery date of the product and the calendar CAL are read.
The planned delivery date of the purchased product is calculated based on 2, and the required amount of the purchased product is added to the planned delivery date of the purchased product required amount bucket 23a and the like (FIG. 15).

The operation of the server program 7 of the present invention will be described below.

First, in the present embodiment, FIG.
As an example, the production management of the product X shown in FIG. 4 and the product Y shown in FIG. As shown in the same figure, this product X is manufactured through the process A by the intermediate products "A" and "I". The intermediate product "A" is the purchased product from the process D, the intermediate product "E". , The intermediate product “i” is a purchased product, and the intermediate product “i” is manufactured through the process C. In addition, product Y is an intermediate product "A".
It is assumed that the intermediate product “U” is manufactured through the process C from the purchased product. The process steps of these products X and Y are summarized in FIG. Therefore, first, the basic data for controlling the production of the products X and Y are input.

(1) Registration of basic data (P1 in FIG. 16) The operator first inputs the production management target products X and Y from the input unit 2.
Enter the "item", "configuration", and "process procedure" of (Figure 1
6P1)

Registration of item master (FIG. 4) As the "item", each product X, Y, intermediate product "A" ~
Each item code (X, Y, a,
Etc.), product name (product X, intermediate product “A”, purchased product, etc.), product classification (information whether products, intermediate products, or purchased products), inventory management, management classification (MRP) Information on whether to manage according to the method or the manufacturing method), internal / external work (information on whether to manufacture internally or externally), unit, maximum and minimum lot size, safety stock amount, fixed damage amount, damage loss Enter the rate and fixed lead time. In the example shown in this embodiment, the proportional lead time is unused (P1 in FIG. 16). The program 7 (item master creating means) creates the item master 13 shown in FIG. 4 based on the above input data, and registers the master 13 in the database 8 (P1 in FIG. 16).

Registration of Configuration Master (FIG. 5 (a)) For the above "configuration", the operator uses the input unit 2 to enter the parent-child relationship (parent item code and child item code) for each item,
The constituent quantity of the parent item and the constituent quantity of the child item relative to the constituent quantity of the parent item are input (see FIG. 5A). For example, for product X, in the case of product X and an intermediate product “A”, product X is a parent item and intermediate product “A” is a child item, and each item code is input as a parent item code and a child item code, and Enter that the parent item component quantity is 1 and the child item component quantity is 1. In the case of the intermediate product “i” and the purchased product, the intermediate product “i” is the parent item, and the purchased product is the child item. Each item code is entered, and the parent item composition quantity is 10 and the child item composition quantity is 10. Is input (see FIG. 5A). The other items and the product Y are input in the same manner. As a result, the program 7 (configuration master creating means) generates the configuration master 14 shown in FIG. 5A based on each input data, and stores the master 14 in the database 8
(P1 in FIG. 16).

When the configuration master 14 is registered, the program 7 is executed on the basis of the configuration master 14 as shown in FIG.
As shown in the parts tables 14a and 14b of (b) and (c), it is possible to recognize the production process including the parent-child relationship between the product X and the product Y.

Registration of Process Procedure Master (FIG. 6) Regarding the above “process procedure”, the operator refers to the process procedure table of FIG. Input process A as a process, process B as a process of intermediate product “A”, process C as a process of intermediate product “I”, and processes for all other items. As a result, the program 7 has the process procedure master 15 shown in FIG.
Is created and the master 15 is registered in the database 8.
Further, at this stage, the operator inputs that the process B is a neck process. This program (process procedure master creating means) adds * to the process B column of the process procedure master 15 on the database 8 and recognizes that the process B is a neck process (FIG. 16P1).

(2) Automatic generation of simple process procedure master (FIG. 16P2, FIG. 17) Next, this program 7 (simple process procedure master creating means 1
00) is the item master 13 (FIG. 4) and the configuration master 14 (FIG. 5) configured on the database 8.
(B)) Based on each data of the process procedure master 15 (FIG. 6), the simplified process procedure master 16 (FIG. 7) is automatically generated and the master 16 is registered in the database 8 (FIG. 16).
P2).

The simple process procedure master 16 is the first process (process D) among the processes from the time when the bottom-level purchased product (for example, purchased product) is shipped to the top-level product X in the production process having the neck process. ) To neck process B
Lead time (preceding process lead time), lead time from neck process B to product X (post process lead time), and the whole production process is centered around neck process B and the lead time before and after the above process is simplified. It is a representation. Specifically, as shown in FIG. 17, the post-process lead time of the product X refers to the process procedure master 15, and the neck process B recognizes that it is a process of manufacturing the intermediate product “A” (FIG. 17P2-1) and further referring to the configuration master 14 to recognize that the intermediate product “A” exists from the neck process B to the product X (child item “A” → parent item “Product X”).
(Fig. 17P2-2), the fixed lead time = 1 day of the intermediate product "A" is read from the item master 13 (Fig. 17P).
2-3), the lead time (1 day) is registered as the post-process lead time (P2-5 in FIG. 17). In the present embodiment, in the process from the neck process B to the product X, 1
Since there is one intermediate product "A", the fixed lead time of the intermediate product "A" is the post-process lead time. However, when there are a plurality of intermediate products as shown in FIG. "O" or "ka"), each intermediate product "O" or "ka"
Fixed lead time is added (FIG. 17P2-4), and the added lead time is registered as the post-process lead time (FIG. 17P2-5).

For the pre-process lead time of the product X, referring to the configuration master 14, it is recognized that the intermediate product "E" exists from the purchased product to the neck process B of the intermediate product "A" (child). Item purchased item → parent item “e”, parent item “e” → child item “a”) (FIG. 17P2-6), and fixed lead time = 1 day of the intermediate product “e” is read from the item master 13 ( 17P2-7), the lead time (1 day) is registered as the previous process lead time (FIG. 17P2-9).
In this case as well, since there is one intermediate product “e” in the process from the purchased product to the neck process B, the fixed lead time of the intermediate product “e” becomes the previous process lead time. As shown in FIG. 23, when there are a plurality of intermediate products (intermediate product “ki” “ku”), the fixed lead time of each intermediate product “ki” “ku” is added in the same manner as above ( 17P2-8), the added lead time is registered as the previous process lead time (FIG. 17P2-9). Furthermore, the program 7 has the neck process as the process B,
Also, referring to the composition master 14, it recognizes that the child item composition quantity for the parent item composition quantity (product X) 1 of the intermediate product “A” is 1, and registers that the neck process item unit quantity is 1 ( 17P2-10). Further, it is registered that the post-process calendar (described later) is CAL1 and that the pre-process calendar (described later) is CAL2 (FIG. 17P2-1).
1). It should be noted that the same information is input for the product Y, but since the process procedure in which the neck process B exists is the same as that for the product X in the present embodiment, the same data is input for the product Y (FIG. 17P2-12). . Through the above processing, the simplified process procedure master 16 shown in FIG. 7 is automatically generated on the database 8 (P2 in FIG. 16).

(4) Automatic generation of simple purchase product master (Fig. 1
6P2, FIG. 8, FIG. 18) Program 7 (simple purchase product master creating means 109)
8 is based on the respective data of the item master 13 (FIG. 4), the configuration master 14 (FIG. 5 (A)), and the process procedure master 15 (FIG. 6) registered in the database 8 as shown in FIG. The simple purchase product master 17 shown in FIG. 16 is automatically generated and registered in the database 8 (FIG. 16P2).

The simple purchase item master 17 is each purchase item ...
For each product, the purchased product unit quantity, the fixed lead time, and the calendar category are registered for each product. For the purchased product of the product X, the program 7 refers to the structure master 14 of the product X, and the child component quantity of the intermediate product “A”, which is a child item, to the parent product component quantity 1 which is the product X is 1, For the parent component quantity 1 of the parent item, the intermediate product “A”, to the parent component quantity 2 of the child item, the intermediate product “E”, and to the parent component quantity 2 of the parent item, the intermediate product “E” Then, it is detected that the child component quantity of the purchased item as a child item is 1 (Fig. 18P2-13), and regarding the purchased item for the product code X, one product X is required for the product X2. It is detected (FIG. 18P2-14), and it is registered that the product unit quantity is 2 and the purchased product unit quantity is 1 (FIG. 18P2-15).

Regarding the purchased product of the product X, the configuration master 14 of the product X is similarly referred to, and the parent composition of the product X, the parent item composition quantity 1, is the child composition of the intermediate product "I" which is the child item. It is detected that the quantity is 2, and the parent constituent quantity 10 of the intermediate item “i”, which is the parent item, has the child constituent quantity 1, which is the purchased item (FIG. 18P2-13), and the purchase item for the product code X. About 5 of product X, it is an intermediate product “I”
10 pieces (2 × 5) are required, and one purchase item is required for this, so it is calculated and registered that the product unit quantity is 5 and the purchase product unit quantity is 1 (FIG. 18P2-
14, 15). For other purchases of product X,
Similarly, the product unit quantity and the purchase product unit quantity are registered (Fig. 1
8P2-16). Also, for product Y, each purchased product,
Similarly, the product unit quantity and the purchase product unit quantity are registered (Fig. 18P2-17).

Regarding the fixed lead time, the fixed lead time of each purchased product is registered by referring to the item master 13 and the configuration master 14. For example, in the case of a purchased product, it is detected by referring to the configuration master 14 that all the intermediate products from the purchased product to the product X are “A” and “E” (child item purchased product → parent item “E”, Child item "e"-> parent item "A", child item "A"-> parent item product X) (Fig. 18P2-
18), referring to the item master 13, it is detected that the fixed lead times of the product X and the intermediate product "A" and "E" are each one day (Fig. 18P2-19), and the three days obtained by adding these are determined. Register as a fixed lead time (Fig. 18P2-2)
0). Fixed lead times are registered for other purchased products by the same calculation (2 days for purchased products, 2 days for purchased products) (FIG. 18P2-21). As for the calendar classification, since it is a purchased product, the previous process calendar CAL2
Is registered (FIG. 18P2-22). By the above processing,
The simple purchase product master 17 (FIG. 8) shown in FIG. 8 is automatically generated in the database 8 (FIG. 16P2).

(5) Input of resource information (FIG. 16P3, FIG. 9) Next, the operator inputs the resource information from the input unit 2 (FIG. 16P3). As resource information, item codes (X, A, I, etc.) of each product and intermediate products, processes (process A, process B, etc.) corresponding to these item codes, resource codes (lines for producing each process) ), Enter the standard work quantity, standard work time, and standard setup time for each process. In this case, when there are two lines of the same process, both resource codes are input, and the priority order for determining which line has priority is input. For example, it is input that the process for the product X is process A, its resource code is A1, priority 1, standard work quantity 100, standard work time 60 minutes, and standard setup time 15 minutes. Further, for the intermediate product “A”, since there are two lines of the neck process B, the resource codes B1 and B2 are input for each line, and the resource code B1 is set in order to make the line of the resource code B1 a priority resource. Enter “1” in and the resource code B2 in “2”. Other intermediate products "I"
Similarly, each data is input for "U", "E", and product Y. As a result, the program 7 (resource capacity master creating means) creates the resource capacity master 18 shown in FIG. 9 based on the input data, and registers the master 18 on the database (FIG. 16P3).

(6) Calendar registration (FIG. 16P4) Next, the operator performs calendar registration (FIG. 16P4).
Here, the calendar is a table made up of data indicating the maximum operating time (calendar operating time) of the day and the holidays of the line for each year, month, and day (CAL in FIG. 14A).
1, CAL 2). The operator uses the input unit 2 to center the neck process B on the previous process calendar CAL2 (see FIG. 14).
(B)) and the post-process calendar CAL1 (FIG. 14A), the factory holidays and operating hours are input. This program (calendar creating means) creates each of the calendars CAL1 and CAL2 based on the input holidays and the like, and registers them in the database 8.

(7) Other data It should be noted that various production control data based on past orders have already been input to the database 8 and, as shown in FIG. 10, one-day manufacturing for each neck process. Load time, production quantity, item, resource, record classification (arranged load time, confirmed load time, planned load time, etc.) together with date information, capacity requirement table (RCRP detail table) 1
It is stored as 9. That is, capacity requirement table 1
9 indicates, for example, about the neck process B of product X
It is input that the daily load time is 180 minutes (3H).

Further, in the database 8, the required quantity bucket 20a for product effective stock calculation shown in FIG. 11 based on the past orders (the confirmed shipment quantity of the product for each date, the predicted effective stock quantity, etc. are registered. 15) and the required product quantity bucket 23a shown in FIG. 15 (a bucket in which the confirmed delivery quantity of the purchased goods for each date, the estimated stock quantity, etc. are registered) are generated.

This completes the basic data registration process. The delivery date calculation process when an actual order is received will be described below.

(8) Delivery date reply input work (FIG. 16P5, FIG. 19) Here, the delivery date reply processing when there is an order inquiry for the product X with a delivery date of ◯ 9th and a quantity of 100 pieces will be described. . It is assumed that the input date (today) is ◯ 1.

When the above-mentioned order is received, the operator, based on the input screen, first receives the ordered product code X and quantity 10.
0, delivery date (product delivery schedule) ○ Enter the 9th of the month from the input unit 2 (Fig. 19P5-1). Next, this program 7
The effective stock of the product X is calculated by the RP method, and a temporary production plan as to whether or not a temporary production plan can be established is calculated (Fig. 19P5-2, 3). That is, the program 7 is based on the code number and is registered in the database 8 in advance in the required inventory for product effective stock calculation 20a.
((A) in FIG. 11) is searched, and a temporary order entry column 30a is created in the bucket 20a (bucket 20b in (b) in FIG. 11).
100) is registered in the ◯ 9th day column 30 of the provisional order entry column (FIG. 11B, FIG. 19P5-2), and a provisional production schedule column 31a is created in the bucket 20a (see FIG. 1
1 (b) bucket 20b), and 100 is registered in the ◯ 9th day column 31 of the provisional production schedule column (FIG. 19P5-).
3, refer to the required amount bucket 20b in FIG. Here, the program 7 searches the available stock forecast column 32 of the required amount bucket 20a, and determines whether 100 is shipped on ◯ 9 and whether or not there is available stock on the same day (P5 in FIG. 19).
-6) For example, when it is determined that there are 200 or more effective stocks on ◯ 9, it can be determined that there is no provisional production plan because the order can be processed with the stock (FIG. 19P5). -6 No), the quantity 100 is added to the relevant bucket date 33 (◯ 9th month) corresponding to the delivery confirmation of the required quantity bucket 20a, and the process ends (P5-29 in FIG. 19).

In the present embodiment, as shown in the bucket 20b, since there is no effective stock (stock 0 on ◯ 9), it is judged that there is a tentative production plan (Fig. 19P5).
-6 Yes), next, in order to determine whether or not the product X can be produced by the 9th day of the month, the start date of the neck process B, the delivery date calculation, and the load time calculation are executed (Fig. 19P5-7 and below). .

(A) Calculation of delivery date (neck process delivery date) passing through the neck process, that is, when the neck process B must be passed in order to ship on the 9th day of month ◯. Therefore, the following calculation is performed to calculate the delivery date when passing through the neck process B.

Neck process delivery date = Delivery date (9th month of month) -Post process lead time of simple process procedure ... This program 7 (neck process delivery date calculation means 101)
The simple process procedure master 16 (FIG. 7) of the database 8 is searched, the post process lead time = 1 day for the product X is read (FIG. 19P5-7), and the neck process delivery date = ○ month 8 is calculated from the above formula. (Fig. 19P5-8)
The date is temporarily stored in the RAM 5. As described above, by referring to the simple process procedure master 16, it is possible to quickly calculate the neck process delivery date without the need to calculate the lead time of each intermediate product from the neck process to the product X one by one.

(B) Calculation of Search Start Date for Retrieving Neck Process Next, in order to ship on the 9th day of the month, considering the lead time of the previous process, the neck process that can be started if there is no load is selected. The start date, that is, the search start date, is calculated.

Search start date = Today (1st month of month) + 1 + Previous process lead time of the simple process procedure ... This program 7 (search start date calculation means 102) uses the simple process procedure master 16 (see FIG. 7) of the database 8. ) Is read and the previous process lead time = 1 day for product X is read (FIG. 19P5-9), and the search start date = ○ from the above formula.
The third day of the month is calculated (P5-10 in FIG. 19P), and the third day of the month is temporarily stored in the RAM 5. Also in this case, by referring to the simplified process procedure master 16, it is possible to quickly calculate the search start date without the need for calculation such as adding the lead time of each intermediate product from the purchased product to the neck process.

(C) Calculation of production quantity in neck process Next, the production quantity in neck process B is calculated for the product quantity of the product X. Therefore, the following calculation is performed to calculate the production quantity.

Production quantity of neck process = product quantity × unit quantity of simple process procedure ... This program 7 (neck process production quantity calculation means 103)
Is the simplified process procedure master 16 of the database 8 (FIG. 7).
Search for, and the neck process item unit quantity for product X =
1 is read (Fig. 19P5-11), and the production quantity of neck process B is 100 (100 x 1) based on the ordered quantity of 100.
Is calculated (P5-12 in FIG. 19) and temporarily stored in the RAM 5.

(D) Calculation of load time of neck process resource Next, this program 7 (load time calculation means 104)
Based on the production quantities of the neck processes B1 and B2, the load time in the neck process for producing the production quantity is calculated. Therefore, the following calculation is performed to calculate the load time. Load time = production quantity of neck process / standard work quantity × standard work time + standard setup time ... This program 7 (load time calculation means 104) refers to the resource capacity master 18 (FIG. 9) of the database 8. , The standard work quantity = 50, the standard work time = 60 minutes, and the standard setup time = 60 minutes for the neck process resource B1 (FIG. 20P5-13), and the neck process production quantity (100) calculated by the above formula. Is read from the RAM 5, the above formula is calculated based on these data, the load time for the neck process resource B1 = 180 minutes (3H) is calculated (FIG. 20P5-14), and the calculation result (180 minutes) is RA.
Store once in M5. Further, the neck process resource B2 is similarly calculated with reference to the resource capacity master 18, and the load time = 180 minutes (3H) for the neck process resource B2 is calculated (FIG. 20P5-15), and is temporarily stored in the RAM 5. Remember.

Next, the program 7 (free time determining means 105) searches the free time of the neck process resource. That is, it is determined whether or not the product X can be produced by ◯ 9.

First, the program 7 (neck process load bucket creating means 108) refers to the simplified process procedure master 16 (FIG. 7) of the database 8 and recognizes that the post process calendar for the product X is CAL1. (Fig. 20P
5-16), the calendar CAL1 and the capacity requirement table 19 (FIG. 10) are referred to, and the neck process load bucket 21a shown in FIG. 12A is created (FIG. 20P5-1).
7), register the bucket 21a in the database 8. That is, the neck process load bucket creating means 108.
Refers to the calendar operating time for each date from the calendar CAL1 (FIG. 14), the load time for each date from the capacity requirement table 19 (FIG. 10), and the record classification, and subtracts the load time for that day from the calendar operating time. Calculate free time,
For the neck process B1, a bucket 21a indicating the calendar operating time (maximum operating time), the load time of the day, and the idle time is created for each date. The bucket 22a shown in FIG. 12B is a visual representation of the information of the bucket 21a, and the bucket 22a can be displayed on the display unit 3 by the operation of the operator. For the neck process resource B2, the neck process load bucket 21b (FIG. 12C) and the same bucket 22b (FIG. 12D) are created by the same process (FIG. 20P5-1).
8), registered in the database 8.

Then, the program 7 (free time determining means 105), in the neck process load bucket 21a on the database 8, searches the RAM 5 from the start date (○).
The 3rd month), delivery date (8th month), and load time (3H) are read, and the free time from the neck process search start date (3rd month) to the neck process delivery date (8th month) is backed up. A word or forward search is performed (FIG. 20P5-19) to search whether or not there is a vacant time of the load time 3H for the neck process resource B1. As a result, this program 7 has a free time of 5H (300 minutes) on the 7th day of the month of the neck process resource B1 (see column 34 of the neck process load bucket 21a).
It is detected that there is (neck process resource idle time ≧ load time of the temporary production plan), and production is planned in this load bucket (3
It is determined that (H) can be added (FIG. 20P5-1).
9). Therefore, this program 7 (free time determination means 10
5) adds the load time 3H to the ◯ 7th day column 34 of the load bucket 21a of the neck process resource B1 (Fig. 19P5-2).
0, see neck process load bucket 21a 'in FIG. 13).

If there is no vacancy in the load bucket 21a (FIG. 12) (FIG. 20P5-19, vacant time of neck process resource <load time of temporary production plan), it is searched whether or not there is an alternative resource ( 21P5-25), the load bucket 21b of the neck process resource B2 having a low priority (FIG. 12C).
21P5-26 to 20P5-26 of FIG.
19). If there is no day for which the above-mentioned load time 3H can be added as it is, forward search from the 8th month onward to load time 3
Calculate and display the earliest delivery date when H is satisfied (Fig. 2
1P5-27). Then, the free time of the neck process resources (B1 and B2) from the 3rd to the 8th of the same month is searched to calculate and display the quantity capable of divided production (Fig. 21P5-
28).

This program 7 (delivery date fixing means 107)
In step P5-20, since the load time 3H can be added on the 7th of March, it is determined that the order for the product X is possible, and the required amount bucket 20 for the product X is determined.
b (FIG. 11B), the quantity 100 is added to the shipment confirmation column 35 on the 9th of March (see FIG. 20P5-21, FIG. 11C required quantity bucket 20c). The following lead time is calculated for the production delivery date. Neck process delivery date ◯ 7th month + post-process lead time (1st day) = ○ monthday 8th ... This program 7 (delivery date fixing means 107) is the RAM
5 to read the neck process delivery date ◯ 7, and read the post-process lead time (1 day) from the simplified process procedure master 16 of the database 8 and perform the above calculation to
The day is calculated, and the production quantity 1 from the RAM 5 is calculated.
00 is read out, and the quantity 100 is added to the production schedule column 36 of ◯ 8 on the required quantity bucket 20b of the database 8 (see FIG. 20P5-22, FIG. 11C). After that, the provisional ordering bucket (100) and the provisional production scheduled bucket (100) column 31 of the month 9 column 30 of the requirement bucket 21b of the database 8 are cleared (FIG. 20P).
5-23). As a result, the product effective stock requirement bucket 20c shown in FIG. 11C is generated in the database 8,
Delivery time is calculated.

(9) Calculation of required quantity of purchased products (Fig. 16P6,
22P6-1) Next, this program 7 (purchased product required amount calculation means 111,
The database 8 for calculating the planned delivery date of purchased goods is
With reference to the simple purchase item master 17 of the above, the quantity of purchase items required for the planned production number of 100 pieces on the planned production date ◯ 8 of the product X is calculated.

(A) Purchased Product First, the program 17 (purchased product required amount calculation means 11)
1) refers to the simplified purchase item master 17 (FIG. 8) of the database 8 and recognizes that the purchase item unit quantity is 1 for the product unit quantity 2 (FIG. 22P6-1), and the planned production quantity is 100 pieces. On the other hand, it is calculated that the required quantity of purchased products is 50 (FIG. 22P6-2) and is temporarily stored in the RAM 5. Next, this program 7 (purchased product scheduled date calculation means 110) reads the fixed lead time = 3 days of the purchased product with reference to the simple purchased product master 17, and predicts the scheduled delivery date of the product X (production scheduled). (Sun) ◯ 8th, subtracting the fixed lead time (3rd), ◯ 5th is calculated (Fig. 22P6).
-3), The month 5 is stored in the RAM 5 once. In this way, by referring to the simple purchase product master 17,
When calculating the required quantity and lead time of a purchased product, it is possible to quickly calculate the required quantity and the lead time without calculating the quantity and the lead time for each process procedure. Here, the program 7 (purchased product expected date calculation means 110) refers to the calendar category CAL2 of the purchased product of the simple purchased product master 17 (FIG. 22P6-4),
By referring to the calendar CAL2 (FIG. 14B), it is recognized that ◯ 5 is a holiday. Then, the day before that, that is, ◯ 4th month, is calculated as the scheduled delivery date of the purchased product (Fig. 22P6).
-6), The required amount 50 is read from the RAM 5, and the required amount bucket 23a of the purchased product is obtained (FIG. 15 (a)).
The required amount 50 is added to the ◯ 4th month column 37 (Fig. 22P6).
-6). If the scheduled delivery date is not a holiday, the required amount is added to the bucket on that day (FIG. 22P6-7).

(B) Similar to the purchased product, this program 7 (purchased product required amount calculation means 11)
1) refers to the simple purchase product master 17, and since the purchase product unit quantity is 1 for the product 1, the required quantity of the purchase product is 100 for 100 planned production quantities of the product X. Is calculated (FIGS. 22P6-8, P6-1 and 2), and RA
Store once in M5. Next, the planned purchase item delivery date calculation means 110 refers to the simple purchase item master 17 of the database 8 to read the fixed lead time of the purchased item = 2 days, and from the planned delivery date of the product X, from the 8th month. The fixed lead time is subtracted to calculate the 6th day of the month (Fig. 22P6-
3), temporarily store in RAM5. Here, this program 7 (purchased goods expected date calculation means 110) is the calendar C.
Refer to AL2 (FIG. 14B) (FIG. 22P6-4,
5) Confirm that it is not a holiday on June 6
The day is calculated as the planned delivery date of the purchased product, and the RAM5
The required amount 100 is read from and the required amount 100 is added to the ◯ 6th day column 38 of the required amount bucket 23b (FIG. 15B) of the purchased product (FIG. 22P6-7).

(C) Purchased product Further, this program 7 (purchased product required amount calculation means 11)
1. The purchase item delivery scheduled date calculation means 110) calculates the required amount of the purchased item and the scheduled delivery date by the same method, and calculates the purchase item requirement bucket 23c (FIG. 15C).
The required amount 20 is added to the date column 39 (Figs. 22P6-8 to P8).
6-7, 8).

Through the above processing, the required amount of each purchased product is calculated and the production plan is determined (Fig. 1).
6P7). After that, the required quantity is calculated by the so-called manufacturing method, and finally the effective stock of the purchased product is calculated (FIGS. 16P8 and P9).

As described above, according to the present invention, various master information is registered in advance for the products X and Y, and a simple process procedure master is automatically generated based on these master information. In the delivery date calculation, by referring to the above-mentioned simple process procedure master, the delivery date calculation can be executed quickly by focusing on the neck process, so it is not necessary to calculate the required amount for each process There is an effect that the calculation can be performed extremely quickly.

Further, according to the present invention, various master information is registered in advance for the products X and Y, and a simple purchase product master is automatically generated based on these master information. , By referring to the above simple purchase item master, it is possible to quickly calculate the required amount of the purchased item, so it is not necessary to calculate the required amount for every process, not only the delivery date calculation but also the purchase There is an effect that the required quantity of the product can be calculated extremely quickly.

[0055]

As described above, according to the present invention, various master information is registered in advance for products to be production-controlled, and a simple process procedure master is automatically generated based on these master information to calculate the delivery date of the ordered product. In the above, by referring to the above-mentioned simple process procedure master, the delivery date calculation can be executed promptly by focusing on the neck process, and therefore the delivery date calculation can be executed extremely quickly.

Further, according to the present invention, the simple purchase product master is automatically generated based on the master information, and by referring to the simple purchase product master in the delivery date calculation of the ordered quantity of products, The required amount of purchased items can be calculated quickly, so
The required quantity of purchased products can be calculated extremely quickly.

[Brief description of drawings]

FIG. 1 is a block diagram showing a hardware configuration of a production management system according to the present invention.

2A and 2B are a parts table and a process procedure table for products X and Y, respectively.

FIG. 3 is a parts table / process procedure table in which the process procedure table of FIG. 3 is unified.

FIG. 4 is a diagram showing an item master of the same system.

FIG. 5A is a diagram showing a configuration master of the above system;
(B) and (c) are parts lists of products X and Y, respectively.

FIG. 6 is a diagram showing a process procedure master of the same system.

FIG. 7 is a diagram showing a simplified process procedure master of the same system.

FIG. 8 is a diagram showing a simple purchase product master of the same system.

FIG. 9 is a diagram showing a resource capacity master of the same system.

FIG. 10 Same as above System capacity table capacity table (RCR
It is a figure which shows the P detailed table.

11 (a) to 11 (c) are diagrams showing required product buckets for product effective inventory calculation of the same system.

12A and 12B are diagrams illustrating a neck process resource load bucket of the neck process resource B1, and FIG. 12C is a diagram illustrating a neck process resource load bucket of the neck process resource B2.

13A and 13B are diagrams showing a neck process resource load bucket of the neck process resource B1, and FIG. 13C is a diagram showing a neck process resource load bucket of the neck process resource B2.

FIG. 14 is a diagram showing (a) (b) calendar.

15 (a) to 15 (c) are diagrams showing purchase product requirement buckets.

FIG. 16 is a flowchart showing an operation procedure of the above system.

FIG. 17 is a flowchart showing an operation procedure of the above system.

FIG. 18 is a flowchart showing an operation procedure of the same system.

FIG. 19 is a flowchart showing an operation procedure of the same system.

FIG. 20 is a flowchart showing an operation procedure of the above system.

FIG. 21 is a flowchart showing an operation procedure of the above system.

FIG. 22 is a flowchart showing an operation procedure of the same system.

FIG. 23 is a diagram showing another process procedure.

FIG. 24 is a functional block diagram in which the function of the program of the present invention is divided into blocks.

[Explanation of symbols]

1 server computer 7 server program 8 database 16 Simple process procedure master 17 Simple Purchase Master 18 Resource capacity master B neck process X, Y products ~ Purchased items Ah intermediate product 100 Simple process procedure master creation means 101 Neck process delivery date calculation means 102 Search start date calculation means 103 Neck process quantity calculation means 104 Load time calculation means 105 Free time judging means 107 Delivery time confirmation means 108 Neck process load bucket creation means 109 Simple purchase item master creation means 110 Expected date for purchasing goods 111 Purchased product requirement calculation means

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Mitsuru Sekiguchi             Kitakyushu City Hachiman Nishi Ward 1-16-1, Seita Co., Ltd.             In ceremony company Axis (72) Inventor Toshihiro Ueda             Kitakyushu City Hachiman Nishi Ward 1-16-1, Seita Co., Ltd.             In ceremony company Axis F-term (reference) 3C100 AA08 BB02 BB03 BB05 BB13                       BB14 BB31 BB36

Claims (5)

[Claims] 1. A production management system for performing a production management of a product having at least a neck process between a first process and a final process by a computer, wherein a front process lead time and a rear process lead time centering on the neck process are calculated. And a means for creating a simple process procedure master having the neck process, the unit quantity of the intermediate product produced in the neck process, and the above-mentioned lead time information, and a resource capacity having at least the standard work time information of the neck process. A means for creating a master, a means for calculating the neck process delivery date by subtracting the lead time information after the simplified process procedure master from the planned shipping date of the ordered product, and the above-mentioned simple process based on the quantity of the ordered product. A means for calculating the production quantity of the neck process by referring to the unit quantity of the procedure master, and the production quantity of the neck process A means for calculating the load time of the neck process based on the standard work time of the resource capacity master; and a means for searching the free time of the neck process that can add the load time based on the load time of the neck process, If the load time can be added to the free time found by the search, it is determined that the order can be accepted, and the order quantity is fixed on the date when the order is received. Management system. 2. A means for creating a simple purchase product master having purchase products of each product, unit quantity of purchase products for each product, and lead time information of purchase products is provided. Scheduled delivery of the purchased product by referring to the unit quantity of the purchased product master and calculating the required quantity of the purchased product for the quantity of the ordered product and the lead time information of the simple purchase product master The production management system according to claim 1, further comprising a means for calculating a day. 3. A computer for controlling production of a product in which at least a neck process exists between the first process and the final process, and the neck is calculated by calculating a pre-process lead time and a post-process lead time centering on the neck process. Process, a unit quantity for the product quantity of the intermediate product produced in the neck process, a means for creating a simple process procedure master having both the lead time information, and a resource capacity master having at least the neck process standard work time information Means, means for calculating the neck process delivery date by subtracting lead time information after the simplified process procedure master from the planned shipping date of the ordered product, and unit of the simplified process procedure master based on the quantity of ordered products A means for calculating the production quantity of the neck process by referring to the quantity, and the production quantity of the neck process and the resource capacity master described above. A means for calculating the load time of the neck process based on the semi-working time, a means for searching the available time of the neck process resource that can add the load time based on the load time of the neck process, A computer program for production control, which functions as a means for determining the ordered quantity when the loaded time can be added to the issued free time and determining that the ordered quantity can be accepted and the ordered quantity. 4. The computer program according to claim 3, wherein the computer is caused to function as a means for creating a simple purchase product master having purchase products of each product, unit quantity of the purchase product for each product, and lead time information of the purchase product. Further, when the ordered quantity is fixed, the computer refers to the unit quantity of the simple purchased goods master to calculate the required quantity of the purchased goods with respect to the quantity of the ordered product, and the simple means. A computer program for production control, which functions as a means for calculating the expected delivery date of the purchased item with reference to the lead time information of the purchased item master. 5. A computer-readable recording medium, wherein the computer program for production control according to claim 3 or 4 is recorded.