JP2003186521A - Drawing-up method and provisioning method for speculative production plan for conducting two-step production - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve both the reduction of stocks in possession and requests from clients to supply goods, in a short period by flexibly drawing up a speculative production plan of parts. <P>SOLUTION: A sales management server 40 makes a forecast on the demand of articles (S101) and computes trend in orders representing the distribution of the number of units of the articles ordered and dates of deliveries, based on the demand forecast of articles (S103). A production management server 30 extracts information on the compositions of the parts of the articles, arrangement standard information and running calendar information (S104 to S106). A production plan server 20 draws up the speculative production plan based on the demand forecast, desired delivery dates, trends in the orders, part composition information, the arrangement standard information and the running calendar information (S107) and registers the speculative production plan to the production server 30 (S109). The production plan server 20 extracts information on the stocks in possession and orders arranged already from the production management server 30 (S110 and S111), computes MRP (S112) and registers the orders arranged already to the production management server 30, based on the required net quantities thus computed and the dates of the deliveries (S113). <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 make-to-stock production plan making method and make-to-stock production plan allocation method, and more particularly to a make-to-stock production plan making method and a make-to-stock production plan allocation method for performing two-stage production. Here, the two-stage production means a semi-order production in which expected production and order production are combined. For example, in the case of an automobile, there are cases where the basic parts of the main body are the same, although the colors and options are different. It is often adopted that the production activities are carried out after the order is attached, but such a method is called two-stage production.

[0002]

2. Description of the Related Art As prior art documents for carrying out a two-stage production, JP-A-5-342241 and JP-A-9-30.
No. 0179, etc. are available.

In the "MRP (material requirement planning) method" disclosed in Japanese Patent Laid-Open No. 5-342241, when an ordered product is input to a requirement calculation section, an order allocation calculation section performs order allocation processing. , While the production of products takes place,
The production plan in the production plan storage unit is updated based on the processing result to prevent excessive inventory of products and parts.

Further, the "production management system" disclosed in Japanese Patent Laid-Open No. 9-300179 carries out prospective production of a temporary product name corresponding to a product when pre-required information is input, and finalized order information is input. By assigning this provisional product name to the product, it is possible to realize the prospective production of the product simply by making a simple modification to the production management system for the build-to-order manufacturing.

In these conventional techniques, when a make-to-stock production plan is made in make-to-stock production, it is possible to allocate the make-to-order production plan of any part that is not linked to another order-order to the order-order (general. From the expected production plan of the parts that are not tied to the order order with the old completion date, the estimated production plan of the parts that are not tied to the order order that is close to completion is assigned if there is no inventory). Here, "allocating a make-to-stock production plan" means associating the make-to-stock production plan with an order-order (consuming the make-to-stock production plan).

Generally, the higher the component structure level of a product (hereinafter referred to as a component level) is, the more difficult it is to use the components of the make-to-stock plan. Products can be shipped to customers in a short time. On the other hand, the lower the component level, the more the inventories can be reduced, but it becomes difficult to ship the product to the customer in a short delivery time. That is, the held inventory and the shipping lead time have a trade-off relationship.

[0007]

However, the above-mentioned conventional technique has a problem that the stock of parts tends to increase. The reason is that, without considering the demand forecast and order tendency of the product, the forecast production plan of the component was made by the component allocation (consumption) forecast.

Further, the conventional technique has a problem that it is difficult to shorten the shipping lead time although the parts inventory is likely to increase. The reason for this is that even for an order order for a product that can be made in time by allocating it to a lower-level component, a fixed-component-level component is forecast-produced and the forecast production plan for the component is assigned.

The object of the present invention is to flexibly change the forecast production plan of parts in consideration of the tendency of receiving orders for products and the lead time of each component constituting the product to make a minimum forecast production plan. The purpose of the present invention is to provide a prospective production planning method for carrying out a two-stage production that realizes the above.

Another object of the present invention is to further reduce the stock held by setting a fixed shipping period, which is a period during which product order orders are not accepted.
It is intended to provide a method for making a forecast production plan for performing stepwise production.

Further, another object of the present invention is to extract and extract a prospective production plan for each of the parts that make up the ordered product, and which is within the allocation range in which production can be started after the order date. By assigning the make-to-stock production plan of the part with the lowest part level among the make-to-stock production plan of the parts within the allocatable range to the order order, it is possible to minimize the shipping lead time even with the minimum make-to-stock production plan. The purpose of the present invention is to provide a forecast production plan allocation method for performing the two-stage production.

[0012]

[Problems to be Solved by the Invention] A forecast production planning method for carrying out two-stage production according to the present invention comprises a step of making a product demand forecast, and the number of products ordered and the delivery date based on the product demand forecast. A process of calculating the order tendency showing the distribution,
The process of extracting product component configuration information, ordering criteria information, and operating calendar information, product demand forecast, desired delivery date,
The method is characterized by including a process of making a make-to-stock production plan for each of the parts constituting the product based on the order receiving tendency, the part configuration information, the order reference information, and the operating calendar information.

The make-to-stock production planning method for carrying out the two-stage production according to the present invention is based on the step of making a product demand forecast, the step of setting a shipping fixed period, and the product demand forecast and the shipping fixed period. Process of calculating order tendency that represents distribution of the number of products ordered and delivery date, process of extracting product component configuration information, ordering standard information and operating calendar information, product demand forecast, desired delivery date, order tendency ，
It is characterized by including a process of making a prospective production plan for each part that constitutes a product based on the part configuration information, the order reference information, and the operating calendar information.

Furthermore, the forecast production planning method for carrying out the two-stage production of the present invention is based on the step of making a product demand forecast, the step of setting a fixed shipment period, and the product demand forecast and the fixed shipment period. Process of calculating order tendency that represents distribution of the number of products ordered and delivery date, process of extracting product component configuration information, ordering standard information and operating calendar information, product demand forecast, desired delivery date, order tendency ，
The process of making a make-to-stock production plan for each part that composes the product based on the component configuration information, the ordering standard information, and the operating calendar information, the process of adjusting the make-to-stock production plan, and the adjusted make-to-stock production. The process of registering the plan, the process of extracting the held inventory information and the ordered order, and the material requirement based on the product component configuration information, ordering standard information, operating calendar information, owned inventory information, the ordered order and the expected production plan. It is characterized by including a step of calculating a quantity and a step of registering an arrangement order based on the calculated material requirement.

Furthermore, the prospective production planning method for performing the two-stage production of the present invention performs the two-stage production by the system in which the production planning server, the production management server and the sales management server are connected via the network. In the forecast production planning method, the sales management server makes a demand forecast of a product, and the sales management server,
A step of calculating an ordering tendency indicating the distribution of the number of products ordered and the delivery date based on the demand forecast of the products; and the production planning server, from the production management server, the product component configuration information, the ordering standard information and the operating calendar information. And the production planning server prepares a prospective production plan for each part that composes the product based on the product demand forecast, desired delivery date, order tendency, parts composition information, ordering standard information, and operating calendar information. And a step of performing.

The prospective production planning method for carrying out the two-stage production according to the present invention includes a user terminal, a production planning server,
In a prospective production planning method for performing two-stage production by a system in which a production management server and a sales management server are connected via a network, the sales management server makes a demand forecast for a product, and A step of setting a fixed shipping period; a step of the sales management server calculating an order tendency representing a distribution of the number of products ordered and a delivery date based on the demand forecast of the product and the fixed shipping period of the product; A step of extracting product component configuration information, ordering standard information, and operating calendar information from the production management server; and the production planning server, product demand forecast, desired delivery date, order tendency, component configuration information,
And a process of making a make-to-stock production plan for each component of the product based on the order reference information and the operating calendar information.

Further, the prospective production planning method for performing the two-stage production of the present invention is a two-stage production by a system in which a user terminal, a production planning server, a production management server and a sales management server are connected via a network. In the make-to-stock production planning method, the sales management server makes a product demand forecast, a step of setting a fixed shipping period from the user terminal, and the sales management server makes a product demand forecast and shipment. A step of calculating an order tendency representing the distribution of the number of products ordered and the delivery date based on a fixed period, and the production planning server extracts the parts configuration information of the product, the order reference information, and the operating calendar information from the production management server. And the production planning server, the product demand forecast, desired delivery date, order tendency, parts composition information, and ordering standard information. And the production calendar server, a step of making a make-to-stock production plan of each part that composes the product based on the operating calendar information, a step of adjusting the make-to-stock production plan made from the user terminal, and the production planning server being adjusted. To register the expected production plan of the production planning server in the production planning server, the production planning server extracts the possessed inventory information and the ordered order from the production management server, and the production planning server configures the product component information. The process of calculating the material requirement based on the order reference information, the operating calendar information, the inventory information, the ordered order and the expected production plan, and the production planning server, based on the calculated material requirement, arranges the order. And a step of registering in the production planning server.

On the other hand, the forecast production plan allocation method for performing the two-stage production according to the present invention includes a step of inputting a product order order, product part configuration information, ordering standard information, operating calendar information, possessed inventory information and The process of extracting the arranged order, the process of extracting the expected production plan of the parts that are within the available allocation range for which production can be started after the order date for each of the parts that make up the ordered product, and the extracted allocation is possible A process of allocating a make-to-stock production plan having a part having the lowest part level among the make-to-stock production plans in the range to an order order.

The forecast production plan allocation method for carrying out the two-stage production according to the present invention includes a step of inputting a product order order, product part configuration information, ordering standard information, operating calendar information, possessed inventory information and The process of extracting the arranged order, the process of extracting the expected production plan of the parts that are within the available allocation range for which production can be started after the order date for each of the parts that make up the ordered product, and the extracted allocation is possible Of the make-to-stock production plans of the parts within the range, the process of temporarily assigning the make-to-stock production plan having the lowest part level to the order order and the part-level higher than the make-to-stock production plan of the parts provisionally assigned to the order order A step of temporarily registering an order for parts, a step of returning an answer delivery date which is a calculation result, a step of confirming the response delivery date and confirming an order order,
The method is characterized by including a step of registering the confirmed order order, a step of changing the provisional allocation of the make-to-stock production plan to the main allocation, and a step of changing the temporary registration of the arrangement order to the main registration.

Further, according to the forecast production plan allocation method for carrying out the two-stage production of the present invention, the forecast production plan allocation method for performing the two-stage production by the system in which the user terminal, the production planning server and the production management server are connected via the network. In the production plan allocation method, the step of inputting a product order order from the user terminal, and the production planning server from the production management server, product part configuration information, ordering standard information, operating calendar information, inventory holding information, and ordering. The step of extracting the completed order and the production planning server make a prospective production plan of parts that are in the allocatable range in which production can be started after the order date, for each part that constitutes the product ordered from the production management server. The step of extracting and the production planning server,
It includes a step of allocating a make-to-stock production plan having a part having the lowest part level among the extracted make-to-stock production plans of parts in the allocatable range to an order order.

Furthermore, the prospective production plan allocation method for performing the two-stage production of the present invention is a two-stage production by a system in which a user terminal, a production planning server, a production management server and a sales management server are connected via a network. In the method of allocating expected production plan for performing the process, the step of inputting a product order order from the user terminal, and the production planning server, from the production management server, part configuration information of the product, ordering standard information, operating calendar information, The step of extracting the possessed inventory information and the ordered order, and the production planning server, which is a component constituting a product ordered from the production management server, within a range in which the production can be started after the date of order acceptance. And a production plan of the parts within the extracted allocation possible range by the production planning server. Among the tentatively Hikiateru step the expected production plan part level with the lowest part in order order,
A step in which the production planning server tentatively registers in the production management server an arranging order for a part whose component level is higher than the expected production plan of the part provisionally assigned to the order-accepting order;
The production planning server returns an answer delivery date which is a calculation result to the user terminal, a step of confirming the response delivery date from the user terminal and confirming an order, and the sales management server confirms the confirmed order. The step of registering an order, the step of the production planning server changing the provisional allocation of the expected production plan to the main allocation, and the production planning server changing the arrangement order provisionally registered in the production management server to the main registration. And a step of performing.

On the other hand, the program of the present invention is a procedure for making a demand forecast of a product on a computer, a procedure for calculating an order tendency representing the distribution of the number of products ordered and the delivery date based on the demand forecast of the product, and parts of the product. Procedures for extracting configuration information, ordering criteria information, and operating calendar information, product demand forecasts, desired delivery dates, order trends, parts configuration information,
It is characterized in that a procedure for making a make-to-stock production plan for each component of the product is executed based on the arrangement standard information and the operating calendar information.

Further, the program of the present invention causes a computer to make a demand forecast for a product, a procedure for setting a fixed shipping period, a demand forecast for the product, and a distribution of the number of product orders and delivery dates based on the fixed shipping period. The procedure for calculating the order tendency, the procedure for extracting the product part configuration information, the order reference information, and the working calendar information, and the product demand forecast, the desired delivery date, the order tendency, the part configuration information, the order reference information, and the working calendar. It is characterized in that a procedure for making a make-to-stock production plan for each part constituting a product is executed based on the information.

Furthermore, the program of the present invention causes the computer to make a product demand forecast, a procedure to set a fixed shipping period, a product demand forecast, and a distribution of the number of products ordered and delivery date based on the fixed shipping period. The procedure for calculating the order tendency, the procedure for extracting the product part configuration information, the order reference information, and the working calendar information, the product demand forecast, the desired delivery date, the order tendency, the part configuration information, the order standard information, and the working calendar information. Procedure for making a make-to-stock production plan for each component that makes up the product, a procedure for making adjustments to the made-to-order make-to-stock plan, a procedure for registering an adjusted make-to-stock production plan, inventory information held, and ordered orders. Materials based on the procedure for extracting the product, product part configuration information, ordering standard information, operating calendar information, owned inventory information, ordered orders and expected production plans. Characterized in that to perform the procedure for registering arrange the order based on steps to calculate the principal amount, and the calculated material requirements.

Further, the program of the present invention is a procedure for inputting a product order order to a computer, a product part configuration information, an order reference information, an operating calendar information, a stock inventory information, and a procedure for extracting an ordered order, For each part that composes the ordered product, the procedure for extracting the expected production plan for the parts that can be produced after the ordering date and within the range where allocation can be started, and the expected production plan for the parts that are in the extracted allocation range Among them, it is characterized in that a procedure for allocating a make-to-stock production plan having a part having the lowest part level to an order order is executed.

Further, the program of the present invention is a procedure for inputting a product order order to a computer, a product part configuration information, an order reference information, an operation calendar information, a stock inventory information, and a procedure for extracting an ordered order, an order. For each part that composes the ordered product, the procedure for extracting the prospective production plan of the part that is within the allocation available range after the order date, and the part of the extracted production plan that is within the allocation range Procedure for tentatively allocating a make-to-stock production plan having the lowest part level to an order order, procedure for temporarily registering an order order for a part with a higher component level than the make-to-stock production plan for a part provisionally allocated to an order order, calculation results The procedure for returning the response delivery date, the procedure for confirming the response delivery date, and confirming the order order, the procedure for registering the confirmed order order, and the forecast production total To change the temporary provision of this provision,
In addition, the procedure for changing the provisional registration of the arrangement order to the main registration is executed.

[0027]

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

Referring to FIG. 7, a system to which the forecast production plan planning method and the forecast production plan allocation method for performing the two-stage production according to the first embodiment of the present invention are applied is a user terminal 10, The production planning server 20, the production management server 30, the sales management server 40, and a communication network 100 such as the Internet for connecting them to each other.
And is a system configuration generally called a client / server format.

The user terminal 10 has a plurality of (one in the figure) terminals and is connected to the communication network 100. Depending on the usage of each business person, the production planning server 20,
It has an access right to the production management server 30 and the sales management server 40, and has an inquiry and update function for each information.

Referring to FIG. 1, the processing procedure at the user terminal 10 at the time of making a make-to-stock production plan comprises a fixed shipping period setting step S102 and a make-to-stock production plan adjusting step S108. The fixed shipping period is a period during which the order for the product cannot be accepted unless the period from the order date to the desired delivery date is longer than this.

Referring to FIG. 2, the processing procedure at the time of allocating the expected production plan in the user terminal 10 includes an order entry input step S201, a delivery date reply step S210, and an order acceptance confirmation step S211.

The production planning server 20 prepares and stores an expected production plan of a product, calculates MRP (material requirement plan),
Plan simulation based on the adjustment result of the make-to-stock production plan,
Also, it has a function of storing and managing the parts arrangement plan of the MRP calculation result.

Referring to FIG. 1, the processing procedure when the production planning server 20 makes a make-to-stock production plan comprises a make-to-stock production planning step S107 and an MRP calculation step S112.

Referring to FIG. 2, the processing procedure at the time of allocation of the expected production plan in the production planning server 20 is as follows: the unallocated expected production plan extraction step S207, the expected production plan provisional allocation step S208, and the expected production plan allocation step S213. Consists of.

The production management server 30 has basic production information such as product part configuration information, ordering standard information (lead time from the start of production of each part to completion), supplier information, purchase order. Purchasing management information such as information and supplies, manufacturing management information such as manufacturing order, construction method, manufacturing process, and quality, holding inventory, storage location, acceptance inspection, inventory movement,
It has a function to store and manage the results and history of inventory management information that manages inventory history such as damage and loss, and basic information related to production activities such as cost management information.

Referring to FIG. 1, the processing procedure at the production management server 30 at the time of making a make-to-stock production plan is as follows: component configuration information extraction step S104 and order reference information extraction step S10.
5, operation calendar information extraction step S106, expected production plan registration step S109, possessed inventory information extraction step S110, and arranged order extraction step S111.
And arrangement order registration step S113. Hereinafter, the arrangement order is used as an order including a purchase order (order for purchasing from an outsourced purchaser (business partner)) and a manufacturing order (in-house processing order, so-called manufacturing instruction).

Referring to FIG. 2, the processing procedure at the time of allocating the expected production plan in the production management server 30 is as follows: component configuration information extraction step S202 and arrangement standard information extraction step S20.
3, operation calendar information extraction step S204, possessed inventory information extraction step S205, arranged order extraction step S206, and arranged order temporary registration step S209.
And the arrangement order registration step S214.

The sales management server 40 is a function for registering, storing, and inquiring information about confirmed orders from sales, information on expected orders and accuracy, business negotiation information, sales base inventory information, past sales results, sales trends, and selling information. Have. Further, it has a function of calculating a future demand forecast from past sales results, shipping results, inventory results, seasonal fluctuation factors, special event factors, and the like.

Referring to FIG. 1, the processing procedure at the sales management server 40 at the time of making a prospective production plan includes a demand forecasting step S101 and an order tendency calculating step S103.

Referring to FIG. 2, the processing procedure at the sales management server 40 at the time of allocation of the expected production plan is composed of an order reception order registration step S212.

FIG. 3 is a diagram for explaining the relationship between the order receiving order of products and the inventory (prospect production plan of parts). Referring to FIG. 3, one part A is required to produce one product, and the lead time (time from the start of production to the completion) is one day. Similarly, to produce one part A, part B
1 piece is required and the lead time is 1 day. To produce one part B, one piece C is required and the lead time is 1 day, the part C
It requires 1 piece of material to produce 1 piece, and it takes 3 days from the issue of the order to the shipment of the material. Here, it is assumed that as of the order date, there are two order orders for a product with a delivery date one day (tomorrow) and an order for a product with a delivery date four days later. For order orders for products that are to be delivered one day later (tomorrow), it is necessary to make a part of the parts A in anticipation of production, and to stock them, but for orders for products that are four days later to be delivered, parts A
You don't have to make a stock and make a stock of it, but you can stock a material that can be reused.

FIG. 4 is a bar graph showing a product order tendency obtained when the total number of ordered products of a certain product per day is sorted according to the desired delivery date based on the past order results. Hereinafter, it is assumed that the product having the ordering tendency shown in FIG. 4 has the component structure of the product shown in FIG.

FIG. 5 is a diagram for explaining the calculation of the number of vehicles produced per day. FIG. 3 shows the product component structure, FIG. 4 shows the product order tendency per day, and FIG. 5 shows the product order tendency per day. 1
For the estimated production volume per day, refer to the part that has "prospect" written in front of the quantity. The part in which only the quantity is listed is the part that can be produced if the product is manufactured after the order is placed. Referring to FIG. 5, since 10 orders are received for products with a later delivery date, it is necessary to prepare 10 parts A per day. Similarly, 20 parts B per day for 20 orders for products with 2 days later delivery, 30 parts C per day for 30 orders for products with 3 days later delivery, and materials are arranged. Since it takes 3 days,
3 per day for 30 orders for products with 4 days after delivery
0 for 1 for 10 orders for products with 5 days delivery
It is necessary to prepare 10 pieces per day. Therefore, the number of materials per day is 40. From the above, the daily expected production plan for products is 10 parts A and 20 parts B.
The number of parts, the number of parts C is 30, and the number of materials is 40 (in this case, the daily order quantity 100 is expected to increase / decrease due to seasonal factors, event factors such as sales expansion measures, inventory planning to prevent out-of-stock items. Etc. are taken into consideration).

FIG. 6 is a diagram for explaining the number of units produced in succession as a forecast production plan. Assuming that a product make-up plan is made based on the theory shown in FIG. 5 from the product component structure shown in FIG. 3 and the product order tendency shown in FIG. 4, the product make-up as shown in FIG. A plan is drawn up. For details, in Fig. 5, calculate the number of vehicles produced per day.
In FIG. 6, the number of products produced in succession is described as the expected production plan of parts. That is, in FIG. 6, the quantity required to be prepared per day is represented as an expected production plan for parts by continuing for a plurality of days. Referring to FIG. 6, the expected production plans of all the parts are 3
If 5 orders are received for a product with late delivery (10/13), searching for a prospective production plan for an unallocated part by tracing the parts composition of the product will result in a part scheduled to be completed on the order date (10/10). If you start production from part B using C, product 5
You can see that the unit can be shipped on the desired delivery date. Therefore, 5 of the expected production plan 30 of the part C are allocated and
Moreover, the production order of the product is 5 units on October 13th, part A
The manufacturing order of 5 is added on October 12, and the manufacturing order of the part B is added on October 11. Here, “adding a manufacturing order” means adding as a new order (without consuming the expected production plan).

Next, a forecast production plan planning method and a forecast production plan allocation method for performing the two-stage production according to the first embodiment configured as described above will be described with reference to FIGS. 1 to 6. To do.

(1) Processing procedure from forecast production planning to MRP calculation (see FIG. 1)

First, the sales management server 40 makes a product demand forecast (step S101). Generally, in consideration of past sales results, sales promotion events at dealers, seasonal fluctuations in sales volume, market trends at the time of launching new products, the ratio of in-house products to the sales volume of the entire industry, etc. Set a sales target and decide the monthly / weekly / day product production volume based on the sales target. Production volume per day in Figure 3 1
00 is the number of vehicles produced per day established through the demand forecast.

Next, a fixed shipping period is set from the user terminal 10 (step S102). Setting a fixed shipping period means not accepting an order for the latest product (for example, a fixed shipping period of 2 days is an order for a product that comes in today, and the desired delivery date is tomorrow or tomorrow). It turns out that. Therefore, the ordering tendency of the products shown in FIG. 4 changes. Since it is not necessary to prepare the inventory to meet the order order of the latest product, the inventory held is reduced. By setting the fixed shipping period, the order of products ordered on the order date becomes zero for the products required to be shipped within the fixed shipping period from the order date. A make-to-stock production plan is created for parts at multiple parts levels according to the ordering tendency of the product and the lead times of the parts that make up the product. It will not be done. Therefore, by setting the fixed shipping period, the parts at the parts level are changed as a result.

Next, the sales management server 40 calculates an order-receiving tendency showing the distribution of the number of products ordered and the delivery date based on the product demand forecast (step S103). For example, the order received for a product received today is 3 days after delivery (tomorrow), 4 days after 2 days (tomorrow), 5 days after delivery (5 days after), and the order received for products received yesterday. 1 day later (tomorrow) Delivery time 2 units, 2 days later (tomorrow day)
Delivery date is 2 units, 3 days later (apparently later) delivery date is 5 units, the order received for products received the day before yesterday is 1 day later (tomorrow) delivery date is 1
Unit, 2 days later (the day after tomorrow) Delivery time is 5 units, 3 days later (the day after tomorrow)
If the delivery date is 5, the percentage of the number of units you want one day later is (3 + 2 + 1) ÷ (3 + 4 + 5 + 2 + 2 + 5 + 1
+ 5 + 5) × 100 (%) = 18.75 (%), the percentage of the number of units you want after 2 days is (4 + 2 + 5) ÷ (3 + 4 +
5 + 2 + 2 + 5 + 1 + 5 + 5) × 100 (%) = 34.
375 (%), the percentage of the number you want after 3 days is (5+
5 + 5) ÷ (3 + 4 + 5 + 2 + 2 + 5 + 1 + 5 + 5) ×
100 (%) = 46.875%. If the number of vehicles produced per day is 10, the breakdown of the number of vehicles produced will be 2 after 1 day (decimal point, rounded off, the same applies below), 3 after 2 days,
It can be expected that this will be the production volume to meet the order order for the product of 5 units in 3 days.

Subsequently, the production planning server 20 extracts the component configuration information of the product, the order reference information (lead time), and the operating calendar information from the production management server 30 (steps S104, S105, S106). In the production management server 30, the component configuration information of the product, the order reference information, and the operating calendar information are registered in the database as production basic information. The information in this database is converted into SQL (Structured Query).
Extract with Langue).

Next, in the production planning server 20, based on the product demand forecast, desired delivery date, order tendency, parts composition information, ordering standard information (lead time), and operating calendar information, each part of the product is composed. A forecast production plan of (step S107). For example, from the product production quantity and the product ordering tendency of FIG. 4, it is possible to consider the daily production forecast of parts in FIG. 5 and the daily production forecast of parts in FIG. A make-to-stock production plan is created.
By taking into consideration the ordering tendency of the product and the lead time of each component constituting the product, it is possible to obtain the expected production plan of the component which is reduced as much as possible.

Subsequently, the user terminal 10 makes adjustments to the planned production schedule (step S10).
8). Specifically, using the online screen, etc., the planned production plan is referred to, and based on the experience and intuition of the person in charge of the plan while confirming the plant operation rate, process load balance, capacity, etc. Adjust the increase / decrease in the expected production plan.

Next, the production planning server 20 registers the adjusted expected production plan in the production management server 30 (step S109).

Subsequently, the production planning server 20 extracts the possessed inventory information and the arranged order (ordered purchase order, manufacturing instructed manufacturing order) from the production management server 30 (steps S110 and S111).

Next, the production planning server 20 calculates the MRP based on the product component configuration information, the ordering reference information (lead time), the operating calendar information, the inventory information, the ordered order, and the expected production plan (step). S112). M
In the RP calculation, when you input the information that you want how many products on a certain day and on a certain day, the net requirement amount and how many parts at each component level are needed on a certain day and on a certain day Output the delivery date. In addition, if there is an inventory of parts at each part level or if there is an ordered order, the result that the shortage is the number of months, days, and other items is also output.

Subsequently, the production planning server 20 registers the arrangement order in the production management server 30 based on the net requirement amount and the delivery date calculated as the result of the MRP calculation (step S113).

(2) Processing procedure up to acceptance and allocation of order orders (see FIG. 2)

First, when a product order is input at the user terminal 10 (step S201), the production planning server 2
0 is accepted.

The production planning server 20 extracts the product component configuration information, the ordering reference information, the operating calendar information, the holding inventory information, and the ordered order from the production management server 30 (steps S202 to S206).

Next, the production planning server 20 makes a prospective production plan for each of the parts that make up the ordered product, and is within the allocatable range where production can be started after the order date (FIG. 6).
(Triangle part of) is extracted (step S207). For example, in FIG. 6, five products are required on October 13th. Since the lead time from the part A to the product is one day, five parts A are required every 10/12. Similarly, since the lead time for the component B to become the component A is one day, five components B are required on October 11th. Similarly, the lead time until the part C becomes the part B is one day, and therefore five parts C are required on October 10th. Since the lead time until the material becomes the part C is 1 day, 5 pieces of material are required for 10/9. It takes 3 days from ordering to shipping, so it is necessary to order 5 pieces of material on 10/6. Since the order date is October 10, the production of the component B must be started using at least the component C in time. Make-to-stock production planning is based on the premise that parts at each part level will be completed as planned. Part C, part B, scheduled to be completed on the order date (10/10)
Expected production plan of part A and expected production plan of parts B and A scheduled to be completed tomorrow (10/11)
2) The expected production plan of the part A, which is scheduled to be completed, is the range in which the expected production plan can be allocated.

Subsequently, the production planning server 20 orders the prospective production plan having the lowest component level among the extracted prospective production plans (triangles in FIG. 6) of the components in the allocatable range. Tentatively (step S20
8). At this time, if there is a make-to-stock production plan for a plurality of parts at the lowest part level, the make-to-stock production plan for the part with the latest delivery date is assigned to the order order. An object of the present invention is to make a plan with a forecasted production plan of a minimum number of parts and effectively utilize the ordering order of products. Since the make-to-stock production plan for parts is kept to a minimum, the make-to-stock production plan for parts must be set aside for ordering orders for products with short lead times before shipment. Therefore, after receiving the order reception order for the product, the order preparation order for which the production of the parts having the lowest part level can be started is additionally created.

Next, the production planning server 20 arranges parts (manufacturing orders, purchase orders) whose parts level is higher than the expected production plan of the parts assigned to the order receiving order.
Is temporarily registered in the production management server 30 (step S20).
9). At this time, it is possible to identify that the added order order has been added due to the product order order. There are various identification methods, but identification information may be added to the production order number and purchase order number (identification key of the arrangement order), or the product order order is registered in another field of the production order and purchase order. You may add the item to do. In addition, the sales staff will be notified of order orders for products that cannot be allocated and whose delivery time will be delayed. Here, “the delivery date is broken” means that there is no expected production plan of parts that can be allocated to meet the desired delivery date, and the desired delivery date cannot be kept. "There is no forecast production plan for parts that can be allocated"
The fact that the allocation possible range (triangle part) in FIG. 6 has already been allocated to the order receiving order for other products, and there is no prospective production plan for unallocated parts. However, as a result of expanding the ordered product to the parts with the lowest level of parts, if the production start of the parts with the lowest level of parts is in time after the order date, the expected production plan of the parts will be set for the order. Add allocation orders for all parts at the parts level that make up the ordered product without allocation.

Subsequently, the production planning server 20 returns the reply delivery date, which is the calculation result, to the user terminal 10 (step S210).

The user terminal 10 confirms the reply delivery date,
If so, the order is confirmed (step S21).
1).

Then, the sales management server 40 registers the order reception order (step S212), and the production planning server 2
At 0, the temporary allocation of the expected production plan is changed to the main allocation (step S213), and the production management server 30 changes the temporary registration of the arrangement order to the main registration (step S214).

By the way, the prospective production plan planning method and the prospective production plan allocation method for carrying out the two-stage production of the present invention can be realized by using an ordinary computer system. For example, a computer system that stores a program (a floppy (registered trademark) disk, a CD-ROM, or the like) storing a program that realizes the forecast production plan planning method and the forecast production plan allocation method for performing the two-stage production of the present invention. By installing the product in the above-mentioned manner, the forecast production planning method and the forecast production planning allocation method for carrying out the two-stage production of the present invention can be executed.

The medium for supplying the program to the computer system may be a communication medium (a medium for temporarily and fluidly holding the program such as a communication line, a communication network, a communication system).

[0068]

The first effect is that it can contribute to the reduction of holding inventory. The reason is that performing production activities according to the forecast production plan has a risk that the stock inventories expands as much as the product can be shipped in a short delivery time. This is because the risk is reduced as much as possible by taking into consideration the lead time of each component that constitutes the product, and therefore the risk of expected production is reduced to the utmost limit.

The second effect is that by setting a fixed shipping period, which is a period during which product order orders are not accepted,
This means that the stock held will be further reduced. The reason is,
This is because the order for the latest product will not be accepted, so the tendency of order for the product changes, and it is not necessary to prepare an inventory to meet the order for the latest product.

The third effect is that the shipping lead time can be minimized even if a minimum expected production plan is prepared.
The reason is that, for each part that composes the ordered product, a prospective production plan for a part that is within the allocation range that can start production after the order date is extracted, and the prospective production of the part within the extracted allocation range is available. This is because the make-to-stock production plan of the part having the lowest part level in the plan is assigned to the order receiving order.

[Brief description of drawings]

FIG. 1 is a flowchart illustrating a processing procedure at the time of making a make-to-stock production plan in a make-to-stock production plan making method for performing two-stage production according to the first embodiment of the present invention.

FIG. 2 is a flowchart illustrating a processing procedure at the time of allocation of a make-to-stock production plan in the make-to-make production plan allocating method for performing the two-stage production according to the first embodiment of the present invention.

FIG. 3 is a product ordering order and inventory in a make-to-stock production planning method and a make-to-stock production plan allocating method for performing two-step production according to the first embodiment (stock production plan of parts)
It is a figure explaining the relationship with.

FIG. 4 is a delivery date of the total number of orders received per day for a certain product based on the past order record in the forecast production planning method and the forecast production plan allocation method for performing the two-stage production according to the first embodiment. It is a bar graph obtained when sorted by day.

FIG. 5 is a diagram illustrating the calculation of the number of vehicles produced per day in the forecast production planning method and the forecast production plan allocation method for performing the two-stage production according to the first embodiment.

FIG. 6 is a diagram for explaining the number of production units in a case where continuous production is performed as a production forecast in the production forecast planning method and the production forecast allocation method for performing the two-stage production according to the first embodiment.

FIG. 7 is a block diagram showing a configuration of a system to which a make-to-stock production plan drafting method and a make-to-stock production plan allocation method for performing two-stage production according to the first embodiment is applied.

[Explanation of symbols]

10 user terminals 20 Production Planning Server 30 Production management server 40 Sales Management Server 100 communication network S101 Demand forecasting step S102 Shipping fixed period setting step S103 Order tendency calculation step S104 Component configuration information extraction step S105 Arrangement standard information extraction step S106 Operation calendar information extraction step S107 Prospect production planning step S108 Prospect production plan adjustment step S109 Make-to-stock production plan registration step S110 Holding inventory information extraction step S111 Arranged order extraction step S112 MRP calculation step S113 Arrangement order registration step S201 Order entry step S202 Parts configuration information extraction step S203 Arrangement standard information extraction step S204 Operation calendar information extraction step S205 Holding inventory information extraction step S206 Arranged order extraction step S207 Unallocated production plan extraction step S208 Prospective production plan provisional allocation step S209 Arrangement order temporary registration step S210 Delivery step answer step S211 Order confirmation step S212 Order-order registration step S213 Prospect production plan allocation step S214 Arrangement order registration step

Claims (15)

[Claims] 1. A process of making a demand forecast of a product, a process of calculating an order tendency showing distribution of the number of products ordered and a delivery date based on the demand forecast of the product, product component configuration information,
The process of extracting the ordering standard information and the operating calendar information, and the forecast production plan of each part that composes the product based on the product demand forecast, the desired delivery date, the order tendency, the part composition information, the ordering standard information, and the working calendar information. A method for making a prospective production plan for carrying out a two-stage production, characterized by including a planning process. 2. A process of making a demand forecast for a product, a process of setting a fixed shipping period, and a tendency of receiving an order representing the distribution of the number of products ordered and the delivery date based on the demand forecast of the product and the fixed shipping period. A process and a process of extracting product component configuration information, ordering standard information, and operating calendar information,
A two-step process characterized by including a process of formulating an expected production plan for each component of the product based on the product demand forecast, desired delivery date, order tendency, component configuration information, order reference information, and operating calendar information. A method for making a forecast production plan for production. 3. A process of making a demand forecast of a product, a process of setting a fixed shipping period, and a tendency of receiving an order representing a distribution of the number of ordered products and a delivery date based on the demand forecast of the product and the fixed shipping period. A process and a process of extracting product component configuration information, ordering standard information, and operating calendar information,
Based on the product demand forecast, desired delivery date, order tendency, parts configuration information, ordering standard information, and operating calendar information, the process of making a forecast production plan for each component that makes up the product and the planned production plan Adjustment process, the process of registering the adjusted make-to-stock production plan, the process of extracting the possessed inventory information and the ordered order, the product component configuration information, the order reference information, the operating calendar information, the owned inventory information,
A prospect for performing a two-stage production characterized by including a step of calculating a material requirement based on an arranged order and a forecast production plan, and a step of registering an arranged order based on the calculated material requirement. Production planning method. 4. A prospective production planning method for performing two-stage production by a system in which a production planning server, a production management server, and a sales management server are connected via a network, wherein the sales management server predicts demand for products. And a step of the sales management server calculating an order tendency indicating the distribution of the number of products ordered and the delivery date based on the demand forecast of the product, and the production planning server The process of extracting the component configuration information, the order reference information, and the operating calendar information, and the production planning server, based on the product demand forecast, the desired delivery date, the order tendency, the component configuration information, the order reference information, and the operating calendar information, the product. For making a two-stage production, including a process for making a make-to-stock production plan for each part that constitutes the 5. A prospective production planning method for performing two-stage production by a system in which a user terminal, a production planning server, a production management server, and a sales management server are connected via a network, wherein the sales management server is a product. And a step of setting a fixed shipping period from the user terminal, and the sales management server receives orders indicating the distribution of the number of ordered products and the delivery date based on the demand forecast of the product and the fixed shipping period. The process of calculating the trend,
A step in which the production planning server extracts part configuration information, order reference information, and operating calendar information of the product from the production management server; and the production planning server, product demand forecast, desired delivery date, order tendency, part configuration A method for making a prospective production plan for carrying out a two-stage production, characterized by including a process for making a prospective production plan for each part constituting a product on the basis of information, ordering standard information and operating calendar information. 6. A prospective production planning method for performing two-stage production by a system in which a user terminal, a production planning server, a production management server, and a sales management server are connected via a network, wherein the sales management server is a product. And a step of setting a fixed shipping period from the user terminal, and the sales management server receives orders indicating the distribution of the number of ordered products and the delivery date based on the demand forecast of the product and the fixed shipping period. The process of calculating the trend,
A step in which the production planning server extracts part configuration information, order reference information, and operating calendar information of the product from the production management server; and the production planning server, product demand forecast, desired delivery date, order tendency, part configuration A step of making a make-to-stock production plan for each component of the product based on the information, order reference information, and operating calendar information; a step of making adjustments to the make-to-stock production plan made from the user terminal; The server registers the adjusted expected production plan in the production planning server, the production planning server extracts the inventory information and the ordered order from the production management server, and the production planning server, Calculate material requirements based on product component configuration information, ordering criteria information, operating calendar information, inventory holding information, ordered orders, and make-to-stock plans. Degree and the production plan server, expected production planning method for performing a two-stage production which comprises a step of registering arrange the order based on the material requirements calculated for the production planning server. 7. A step of inputting a product order order, a step of extracting product part configuration information, ordering standard information, operating calendar information, owned inventory information, and an ordered order, and configuring the ordered product. For each part, the part level is the lowest among the process of extracting the prospective production plan of the parts that are within the allocatable range that can start production after the order date and the prospective production plan of the parts that are in the extracted allocatable range. A method for allocating a prospective production plan for performing two-stage production, comprising the step of allocating a prospective production plan having parts to an order. 8. A process of inputting a product order order, a process of extracting product component structure information, ordering standard information, operating calendar information, owned inventory information, and an ordered order, and configuring the ordered product. For each part, the part level is the lowest among the process of extracting the prospective production plan of the parts that are within the allocatable range that can start production after the order date and the prospective production plan of the parts that are in the extracted allocatable range. The process of tentatively allocating a make-to-stock production plan with parts to an order order, the process of tentatively registering an ordering order for a part whose component level is higher than the make-to-stock production plan of the part tentatively allocated to the order order, and the answer delivery date that is the calculation result. Process of returning the order, confirming the response delivery date and confirming the order order, the step of registering the confirmed order order, and changing the provisional allocation of the make-to-stock production plan to the main allocation Degree and, expected production plan provision method for performing a two-stage production which comprises a step of changing the temporary registration arrangements order to registration. 9. A method of allocating a production schedule for performing a two-stage production by a system in which a user terminal, a production planning server and a production management server are connected via a network, wherein a product order order is input from the user terminal. And a step of the production planning server extracting product part configuration information, order reference information, operating calendar information, owned inventory information, and an ordered order from the production management server; and the production planning server performing the production management. A step of extracting a prospective production plan of a part that is within a provisionable range in which production can be started after the ordering date for each part that constitutes the product ordered from the server, and the production planning server extracts the allocated range Of the parts of the production schedule of the parts in the Expected production plan provision method for performing a two-stage production, characterized in that. 10. A method of allocating a product from a user terminal in a prospective production plan allocation method for performing two-stage production by a system in which a user terminal, a production planning server, a production management server and a sales management server are connected via a network. The step of inputting an order, the step of the production planning server extracting from the production management server the component configuration information of the product, the order reference information, the operating calendar information, the stock information on inventory, and the ordered order, and the production planning server. , A step of extracting a prospective production plan of each part constituting a product ordered from the production management server and within a range in which allocation can be started after the order date, and the production planning server is extracted. The temporary production plan that has the lowest component level among the forecast production plans for the parts that are within the available allocation range The step of allocating, the step of the production planning server, the step of tentatively registering in the production management server the arrangement order of the parts whose component level is higher than the expected production plan of the parts provisionally allocated to the order order, and the production planning server, A step of returning an answer delivery date which is a calculation result to the user terminal, a step of confirming the response delivery date from the user terminal and confirming an order, and the sales management server,
The step of registering the confirmed order order, the step of the production planning server changing the provisional allocation of the make-to-stock production plan to the main allocation, and the production planning server storing the order order provisionally registered in the production management server. A prospective production plan allocation method for performing two-stage production, characterized by including a step of changing to main registration. 11. A procedure for making a demand forecast for a product on a computer, a procedure for calculating an order tendency representing a distribution of the number of products ordered and a delivery date based on the demand forecast for the product, product component configuration information, and ordering standard information. And procedure for extracting operating calendar information, product demand forecast, desired delivery date,
A program for executing a procedure to make a make-to-stock production plan for each part that makes up a product based on order trends, part configuration information, order reference information, and operating calendar information. 12. A computer is used to calculate a product demand forecast, a procedure for setting a fixed shipping period, a product demand forecast, and a product order forecast showing the distribution of delivery dates based on the fixed shipping period. To extract the product based on the procedure to perform, the part configuration information of the product, the order reference information, and the operation calendar information, and the product demand forecast, the desired delivery date, the order tendency, the part configuration information, the order reference information, and the operation calendar information. A program for executing the procedure to make a make-to-stock production plan for each component. 13. A computer is used to calculate a product demand forecast, a procedure for setting a fixed shipment period, a product demand forecast, and an order tendency indicating a distribution of delivery dates based on the fixed shipment period. The product is configured based on the procedure for extracting, product part configuration information, order reference information, and operating calendar information, product demand forecast, desired delivery date, order tendency, part configuration information, order reference information, and operating calendar information. To make a make-to-stock production plan for each part, to make adjustments to the made-to-order make-to-stock production plan,
Procedures for registering adjusted make-to-stock production plans, procedures for extracting held inventory information and ordered orders, product component configuration information, ordering criteria information, operating calendar information, owned inventory information,
A program for executing the procedure to calculate the material requirement based on the arranged order and the make-to-stock production plan, and the procedure to register the arranged order based on the calculated material requirement. 14. A procedure for inputting a product order order to a computer, a product part configuration information, an order reference information, an operating calendar information, a stock inventory information and a procedure for extracting an ordered order, and a product for which an order is ordered. For each part to
Procedure to extract the expected production plan of parts that are within the allocation range where production can be started after the date of order, and the expected production plan of the parts that are within the allocation range that is extracted Program to execute the procedure to allocate production plan to order. 15. A procedure for inputting a product order order to a computer, a product part configuration information, an order reference information, an operating calendar information, a stock inventory information and a procedure for extracting an ordered order, and a product ordered. For each part to
A procedure for extracting a make-to-stock production plan for parts that can be allocated after the date of ordering, and a make-to-stock production that has the lowest part level in the make-to-stock production plan for parts that are in the extracted allowance range Procedures for tentatively allocating plans to order orders, procedures for tentatively registering order orders for parts whose component level is higher than the expected production plan for parts tentatively allocated for order orders, and procedures for returning an answer delivery date that is the calculation result.
Answer Confirm the delivery date and confirm the order, confirm the confirmed order, change the tentative allocation of the make-to-stock production plan to this allocation, and change the temporary registration of the order to the registration. A program to execute.