JP2004021891A - Production schedule creating system, component delivery instructing system, production schedule creating method and creation support method for production scheduling - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production schedule creating system capable of creating a production schedule leveling fluctuation of production. <P>SOLUTION: The system creates a production scheduling for a production line capable of manufacturing a plurality of types of commodities. In regard to the plurality of types of commodities, data N(i) or the like indicating the number to be delivered and a delivery date required by a customer 2001 is received, and a production frequency is determined per each type of commodity on the basis of a magnitude of a total sum of numbers to be delivered. The production scheduling is created by determining numbers of commodities to be produced in one production by the determined production frequency, and respectively assigning them to production dates selected by the production frequencies. When fluctuation of a total sum of production quantities is larger than a predetermined reference value, production quantities are moved to other operation dates in order of commodities with smaller production frequencies to level off the production scheduling. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
[0002]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to supply chain management (SCM), and more particularly to a production schedule creation method.
[0003]
[Prior art]
In order to meet the consumer's preferences when introducing products (consumer goods) for consumers (end users) into the market, it is required to diversify the products and shorten the delivery time of the products. For example, it is demanded that various types and grades of cars be purchased and delivered quickly for car buyers. Alternatively, if it is a supplier of automotive parts that is a supplier, it is necessary to prepare various parts corresponding to each car manufacturer, each car manufacturer's model, each car manufacturer's grade, etc., and deliver it according to the car manufacturer's desired delivery date. ing.
[0004]
As a production management method to cope with such a problem, the “Kanban system” of Toyota Motor Corporation is famous. Products produced in factories must procure the parts that make up the products, but it is necessary to have a certain amount of surplus inventory and avoid shortages. The kanban system is one system aiming at minimizing surplus inventory so as not to cause a shortage.
[0005]
In addition, procurement of parts to be outsourced is performed by issuing a delivery instruction to a subcontractor that produces the parts. Ideally, if a subcontractor has the necessary parts delivered in the required quantity and at the required timing and can be put into the production line, there is no need for excess inventory and no shortage. .
[0006]
When a car maker delivers a production goods car to an end user, or when a subcontractor delivers a production goods part to a car maker, shipment and production from receiving a customer request until actually delivering the production goods Operations such as material procurement are performed in accordance with a shipping plan, a production plan, a procurement plan, and the like. However, the shipment plan, the production plan, and the procurement plan could not always be synchronized with each other. One of the reasons is that it is difficult to forecast the future because the amount of production goods required by customers fluctuates. In addition, the production amount may not be constant and may vary due to the size of the production line, the difference in seasonal seasons, the timing of line operation between the company and the subcontractor, and the like.
[0007]
Under such circumstances, it was difficult to formulate a production plan using a computer program and operate the line. This is because the program must be rewritten each time the customer's requirements change, and the program must be designed in consideration of the size of the production line, differences in seasonal seasons, and differences in the line operation timing between the company and the subcontractor. This is because it must be added or changed. Therefore, in the past, in many cases, even if there were fluctuations in each parameter, parts were procured by human tactics that could respond flexibly to these parameters, products (production goods) were manufactured, and delivery was managed somehow. To comply with customer requirements.
[0008]
However, there is a problem that it is difficult to execute a series of tasks promptly in consideration of the overall relevance, because human naval tactics can only provide ad-hoc measures forever. However, there is a problem in that the burden of coping with the situation increases. As a result, there is waste and inefficiency in the production management work itself, and in order to comply with the delivery date, it was necessary to rely on excess inventory.
[0009]
On the other hand, regarding a product (consumer good), for example, Japanese Patent Application Laid-Open No. 2000-293562 provides a production management device capable of coping with surplus inventory. According to this technique, a safety stock amount (excess stock amount) is obtained in consideration of a prediction error obtained from a sales forecast and actual data, and a production amount on a production side is determined. This technique has the effect of shortening the procurement lead time (= the period from when a production plan is drafted to when it becomes possible to start manufacturing the target product after procurement of materials). Further, the present invention enables a factory to make an accurate production plan based on a sales plan of a store, a wholesale shop, or the like that is created at a cycle shorter than the cycle of the production plan created by the factory.
[0010]
In general, in the SCM system, a production plan and a sales plan of a product until a product produced in a factory reaches a consumer through a distribution channel are drafted. For example, in order to efficiently and efficiently distribute products produced in factories, dealers and wholesalers make sales plans by predicting the next sales volume based on past sales volume and other results. On the other hand, the factory predicts the next production amount based on the sales plan, and sets up a production plan with a sufficient production amount in preparation for a problem such as a missing item. It instructs the production of goods according to the production plan.
[0011]
[Problems to be solved by the invention]
Manufacturers that deliver a large amount of production goods based on customer requests proceed with production preparation based on information on the planned number of orders for customers and ship products based on delivery instructions that are firm orders. However, depending on the field, production goods often have a problem that the delivery date cannot be met if production is started after the delivery instruction. This is because the period from the time when a customer's delivery instruction is received to the time when it should be delivered to the customer is called “delivery lead time (LT)”. 1 is referred to as “production lead time (LT)”, and the period from shipment to the customer via the transport route is referred to as “transport lead time (LT)”. As described above, the period obtained by adding the production LT and the transport / delivery LT is often longer than the delivery LT.
[0012]
For example, in the case of a part maker that supplies parts to an automobile maker, as an example of the LT,
Delivery LT $ 60-75 hours (about 3 days)
Production LT $ 100 hours (about 4 days)
Shipping and Delivery LT ≒ 10-24 hours (about 1 day)
It is about. For this reason,
(Delivery LT) <(Production LT) + (Transportation LT) ... (Equation 1)
It becomes.
[0013]
It is not easy to shorten the production LT because a breakthrough in the manufacturing process is required. This is because the production LT is not so long in the case of parts whose manufacture is completed only by assembling (assembly), but parts that require heat treatment or processing take time. In addition, since the transportation and delivery LT largely depends on trucks and ships, it is not easy to shorten the transportation and delivery LT.
[0014]
For this reason, unless the relationship of Expression (1) is resolved, it is impossible to clearly meet the delivery date by starting the production of the product after the delivery instruction. Furthermore, the delivery time cannot be kept in the order-made system. The make-to-order manufacturing method may be effective depending on the field, but in the case of many production goods, it is impossible to respond from the time point of view if an action such as drafting a production plan after confirming the order is taken .
[0015]
For this reason, it is necessary to start the production in consideration of the stock amount based on the information on the planned number of orders, and to prepare for the stocking of material parts necessary for the production.
[0016]
Further, as one of the factors that makes it difficult to create a production schedule, there is a problem that the planned order quantity information does not match the confirmed order quantity. The information that informs the order quantity from the customer includes the estimated order quantity information that informs the approximate order quantity and the confirmed order quantity that informs the exact order quantity. These can be compared to rough cutting (information on the number of planned orders) and finishing (fixed order quantity) in machining.
[0017]
This means that the fixed order quantity will not be determined until just before the delivery date, and the delivery LT tends to be shortened. The reason that the fixed order quantity is not determined until immediately before is due to a mismatch between the production plan of a car maker whose main production is expected production and actual sales of vehicles. Therefore, in order to meet the delivery date, the inventory amount of each production good stored for adjustment to absorb the difference between the planned order quantity and the confirmed order quantity must be increased. With such a concept, in order to prevent out-of-stock items or the like even due to fluctuations in market demand, the ratio of relying on inventory is large, and the problem of having a large amount of inventory cannot be solved in principle.
[0018]
In addition, as mentioned above, while there is a need for an operation method that minimizes the amount of surplus inventory, it is necessary to secure employment on a continuous basis and maintain a uniform work volume in terms of securing local employment and maintaining product quality. (Leveling) is desired. It is desired to make the working style and daily work amount of employees, that is, the production amount as uniform as possible. For example, if it is assumed that a large amount of customer requests are in the winter of bonus sales, it is advantageous for winter shipments if a large number of products are manufactured in the fall and a stock is secured. For this reason, hiring seasonal workers in the fall and using the minimum number of employees in other seasons, or keeping the employment constant and working overtime in the fall to produce a large number of products are available. Conceivable. However, when a seasonal worker is hired, variations in product quality due to different workers and variations in product quality due to a significant difference in the amount of work depending on the season are likely to occur. Also, when a large number of products are manufactured in the fall, several lines with an operation rate of about 200% exist in the fall, but in the other seasons, some of the lines are inefficient when the operation rate is 40%. It is.
[0019]
Also, in the production of production goods, it is important to procure the parts of the production goods in terms of schedule and quantity in accordance with the production of the production goods.
[0020]
An object of the present invention is to create a production schedule in which production amounts are leveled. Another object of the present invention is to provide a production schedule creation system capable of creating such a production schedule.
[0021]
[Means for Solving the Problems]
In order to achieve the above object, the present invention classifies a required quantity from a customer into several types based on the number of products, determines a production frequency according to the classification, and produces a predetermined quantity at the frequency. Things. More specifically, the present invention is to create a production schedule of a production line capable of manufacturing a plurality of types of products, and for the plurality of types of products, data indicating the number of deliveries and delivery date requested by a customer. , The total number of products to be delivered in a predetermined period is obtained for each of a plurality of types of products, and a predetermined production frequency is determined for each type of product based on the magnitude of the total number of products to be delivered. At the determined production frequency, in order to produce the total of the number of deliveries for the predetermined period, the number of commodities to be produced in one production is obtained for each type of the commodities, and the operation day of the production line is determined by the production The production schedule is created by allocating the number of commodities to be produced as production quantities to each of the production dates selected by frequency. Then, a total of the production numbers for a plurality of types of products is obtained for each operating day, and when a variation amount of the obtained total of the production numbers is larger than a predetermined reference value, the production is performed in ascending order of the products having a low production frequency. The production quantity allocated to a day is moved to another operation day, and the production schedule plan is leveled.
[0022]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
[0023]
The present invention is applied to, for example, a production management system 2000 as shown in FIG. The production management system 2000 according to the present embodiment includes an order information collection unit 101 that receives and accumulates product request information from a customer 2001, and a shipping schedule that creates a shipping schedule based on the received information and provides a shipping instruction to a product warehouse. A creation system 103, a production schedule creation system 100 for creating a production schedule from a shipping schedule, and basic information related to production such as a production line capacity of a production section (such as a factory that actually manufactures products) and an operation calendar for each production line. Has a production-related master database 102 pre-stored therein, and a movement grasping device 104 for accepting input of quantities of parts, intermediate products, and finished products existing in various places in the manufacturing department, or detecting the quantities and storing them. are doing. The production management system 2000 is connected to a delivery instruction system 106 that creates a delivery instruction for procuring parts. In the present embodiment, the customer is not a general consumer, but refers to a manufacturing industry, such as a car maker, which performs further processing and assembly after providing the product. Here, the target product is not specified, but may be any product that is manufactured from a member through processes such as processing and assembly.
[0024]
The order information collection unit 101 includes a communication control device that receives, via a network, required product data required by a plurality of customers, and memories 101a, 101b, and 101c that store the received required product data. Have.
[0025]
The production-related master database 102 includes storage devices 102a, 102b, and 102c in which merchandise production capacity for each production line, operating day calendars for the production lines, and production patterns are stored in advance.
[0026]
On the other hand, the movement comprehension device 104 calculates the number of parts received in the receiving part 104a of purchased parts, the number of parts in each part storage area of the production line 104b, the number of intermediate products in the middle of the product manufacturing process, and the number of finished products. It has a collection unit that collects information on the quantity of finished products stored in the product warehouse 104c, and a storage device 104d that stores the information as a database. The collection unit receives the input operation by the worker or receives detection data from a sensor or the like to collect quantity information. The quantity information grasped by the dynamic grasping device 104 is the current quantity information. The number of parts, intermediate products, finished products, and the number of finished products stored in the product warehouse are constantly changing due to the operation of the production line, transportation and delivery to customers, and the receipt of parts. Are collected, and the database of the storage device 104d is updated.
[0027]
The storage device 104d of the movement comprehension device 104 and the storage devices 102a, 102b, 102c of the production-related master data 102 can be constituted by, for example, magnetic disk devices.
[0028]
The shipping schedule creation system 103 includes a shipping schedule creating unit 103a that creates a shipping schedule using the product requirement data received and stored by the order information collection unit 101, and a storage unit 105 that stores the created shipping schedule planning data. Having. The production schedule creation system 100 processes the shipment schedule plan data created by the shipment schedule creation system 103 to produce a production schedule plan, and a storage unit 100b that stores the created production schedule plan data. And
[0029]
The operations of the shipping schedule creating unit 103a of the shipping schedule creating system 103 and the production schedule creating unit 100a of the production schedule creating system 100 will be specifically described.
[0030]
The shipping schedule creation unit 103a has a built-in memory and CPU, and executes a program stored in advance in the memory to create a shipping schedule plan based on the data collected and stored by the order information collection unit 101. . The production schedule creation unit 100a also has a built-in memory and CPU, and creates a production schedule based on a shipment schedule by executing a program stored in the memory in advance.
[0031]
In the present embodiment, the product request information transmitted from the customer includes advance notice information N (i) for announcing the delivery quantity for the next several months and correction information W (i) of the advance notice information N (i). There are three types of determination information D (i) for determining the delivery quantity for the delivery date several days later, and all of them are provided at different timings before the product delivery date. The advance notice information N (i) is information for announcing the daily required delivery quantity for a period of several months, for example, three months from next month, and is transmitted once a month. The notice information N (i) includes the number of delivery requests that are the earliest (until the future) of the three types of information, but is inaccurate and deviates from the confirmation information D (i) that determines the delivery quantity. Is the largest. The correction information W (i) is information for correcting the advance notice information N (i), and is information for announcing a daily requested delivery quantity for the same period (for example, three months) as the advance notice information N (i), and is weekly. Will be sent. Since the transmission timing of the correction information W (i) approaches the delivery date, the deviation from the delivery quantity determined by the determination information D (i) is smaller than the notice information N (i). The confirmation information D (i) is information for confirming the delivery quantity several days later, and is transmitted every day. For example, the confirmation information D (i) is provided 60 hours before the designated delivery time, and immediately before the delivery date with the least time margin. Is required. These pieces of information are stored in a model Kx (x = 1, 2, 3,...) (For example, A1 is a motor, A2 is a piston, etc.) of a product model Ax (x = 1, 2, 3,...) In the case of the product model A1 motor, K1 is a 100φ motor, K2 is a 120φ motor, K3 is a 130φ motor, and so on. These notice information N (i), correction information W (i), and fixed information D (i) are received and stored by the order information collection unit 101.
[0032]
The shipping schedule creation unit 103a creates a shipping schedule plan in units of months using the advance notice information N (i), the correction information W (i), and the fixed information D (i). The shipping schedule plan is a schedule plan that determines, for each product (model Kx of product model Ax), in what month and how many products are to be shipped in order to satisfy the requirements of all customers. The shipping schedule creation unit 103a reads the notice information N (i) from the storage unit 101a of the order information collection unit 101 for each model Kx of the product model Ax, and determines the delivery date (how many months) and the delivery quantity (for that month). (The number of units), the factory operation date with the delivery date advanced by the transport and delivery lead time of the product is set as the shipment date, and the delivery quantity is assigned as the shipment quantity to create a shipment schedule plan (see FIG. 3). S1101). If the date on which the delivery date is brought forward is the day of the factory holiday, it is assigned to the previous working day. As a result, a shipping schedule plan that indicates how many products should be shipped in what month and on what day can be created for the period of the advance notice information N (i). However, the transport / delivery lead time and the operating days of the factory are read from the storage device 102b of the production-related database 102 of the production-related master database 102. Further, if the correction information W (i) is received by the order information collection unit 101, it is read from the storage unit 101b, and the shipping schedule plan is corrected for a part different from the notice information N (i). Further, when the confirmed information D (i) is received by the order information collection unit 101, it is read from the storage unit 101c, and the shipment quantity in the shipping schedule plan is corrected for the confirmed date part. This is performed for all the customers 2001 for the model Kx of the product model Ax, and the shipment quantity to each customer 2001 is added for each shipping date, thereby creating a shipping schedule plan for each model Kx of the product model Ax. . The created shipping schedule plan is stored in the storage unit 105. A shipping schedule plan is created for the model Kx of all product models Ax, and stored in the storage unit 105.
[0033]
Next, the production schedule creating unit 100a creates a supply plan for commodities satisfying the shipping schedule, that is, a production schedule. The production schedule depends on the production capacity, the working day, the material procurement capacity, etc. of the manufacturing department such as a factory for making products, and therefore cannot be the same as the shipment schedule. In the present embodiment, the production schedule creating unit 100a creates a production schedule for each production line MLx (x = 1, 2, 3,...). The production schedule creation unit 100a reads all the models Kx of the product models Ax produced on the production line MLx for creating the production schedule plan from the storage device 102c of the production-related master database 102 (S1100 in FIG. 3). For example, here, it is assumed that the models K1 to K7 of the product model Ax are produced on a certain production line ML1, and a case where a schedule production plan of the production line ML1 is made will be described below.
[0034]
The production schedule creating unit 100a reads the shipping schedule plans from the storage unit 105 of the shipping schedule creating system 103 for the models K1 to K7 of the product model Ax read in S1100 (S1101). When the shipment quantities of the models K1 to K7 are totaled for each shipment date, a shipment schedule plan for the production line ML1 is obtained as shown in FIG. 4, but the shipment quantity of this shipment schedule plan varies greatly depending on the shipment date. In many cases, the variation reaches 50% at the upper and lower limits. As described above, it is desirable that the production schedule quantity be as uniform as possible with as little variation as possible in the shipping schedule plan. For this reason, in the present embodiment, when creating a production schedule, a production pattern is classified for each model Kx of the corresponding product Ax, and leveling can be performed in a later process. When the total of the shipment quantities of Kx within a certain period is Rx, the pattern is classified according to the magnitude of Rx (S1102).
[0035]
The reason why the production pattern is classified based on the total shipment quantity of the model Kx within a certain period is as follows. As schematically shown in FIG. 4, the inventors show that the degree of variation in the daily shipment quantity for each product (model Kx) tends to be depending on whether the shipment volume of the product (model Kx) is large or small. Noticed. For example, if a product (model Kx) is classified into a large-volume product, a medium-volume product, and a small-volume product according to the shipment volume, the fluctuation rate (the difference between the shipment volume on a certain day and the shipment volume on the previous day) is calculated. (The ratio divided by the quantity) tends to be small for large quantities and large for small quantities. Medium-sized products show intermediate properties. Therefore, paying attention to this tendency, in S1102, the production pattern of the product (model Kx) is classified according to the flow shown in FIG.
[0036]
Although the number of classification sections can be set arbitrarily, FIG. 5 illustrates a case where classification is performed into seven types. In the flow of FIG. 5, the models K1 to K7 of the product model Ax produced on the production line ML1 captured in S1101 are classified into seven types based on the shipping quantity, and the production patterns P1 to P7 are automatically classified for each classification. Assignment Specifically, the total Rx of the shipment quantity in a certain period (for example, one month) is calculated for each model Kx (S200), and the total Rx is compared with the pattern determination reference numbers n1 to n6 (S201 to S206). . The judgment reference numbers n1 to n6 are set in advance.
n1> n2> n3> n4> n5> n6 (Equation 2)
Is determined to satisfy the relationship.
A model Kx having a total Rx of n1 or more is produced in a production pattern P1 (S207),
A production pattern P2 (S208), where the model Kx less than n1 and n2 or more,
The production pattern P3 (S209), where the model Kx of less than n2 and n3 or more,
The production pattern P4 (S210), where the model Kx of less than n3 and more than n4 is produced.
A production pattern P5 (S211) with a model Kx less than n4 and more than n5.
The production pattern P6 (S212), where the model Kx less than n5 and n6 or more.
The model Kx less than n6 is classified as a production pattern P7 (S213).
A predetermined production frequency is assigned to each of the production patterns P1 to P7. Here, P1 is produced daily, P2 is produced three times a week, P3 is produced twice a week, P4 is produced once a week, P5 is produced three times a month, P6 is produced twice a month, and P7 is produced once a month. I have. The production pattern determined for each product (model Kx) in S207 to S213 is stored in a built-in memory (S214). In the following description, for convenience, the production pattern P1 for the model K1, the production pattern P2 for the model K2, the production pattern P3 for the model K3, the production pattern P4 for the model K4, the production pattern P5 for the model K5, and S207 to 213 for convenience. The following description is based on the assumption that the production pattern P6 is defined as the model K6 and the production pattern P7 is defined as the model K7.
[0037]
Next, the daily production amount of the line ML1 is determined for each of the production patterns P1 to P7 of the models K1 to K7 (S1103 in FIG. 3). This will be described in detail with reference to the flowcharts of FIGS.
[0038]
The production volume of the product (here, model K1) of the production pattern P1 (daily production) determines the daily production volume according to the flow shown in FIG. First, the number of days D1 for performing the leveling calculation is set (S300 in FIG. 6). The number of days D1 represents the number of days of a period for creating a standardized production schedule plan, and can be arbitrarily determined. For example, D1 can be three months.
[0039]
Next, a theoretical inventory amount G, which is a theoretical inventory amount as of the first day of the calculation target, is calculated based on data acquired from the dynamic management grasping device 104.
G = (inventory amount of the day before calculation processing) + (planned production quantity from the calculation processing day to the day before calculation allocation) − (planned shipment quantity from the calculation processing day to the day before calculation allocation) (Equation 3)
(S301). The calculation processing date is a day on which the production schedule creation unit 100a is performing this calculation, and the day before the first day (first day of calculation allocation) of a date for newly obtaining a production schedule plan by this calculation is the day before calculation allocation.
[0040]
Next, the number of calculation days n is set (S302). n is used as a counter and incremented by one (S303). In S304 and S305, the average shipment quantity H of the model K1 for n days_nAsk for. Specifically, the shipping quantity S of the model K1 on the nth day from the first day of the period for which the production schedule plan is requested (the first day of the calculation allocation)_i(I = 1 to n) are read from the storage unit 105 of the shipping schedule creation system 103 in FIG._n
E_n= ΣS_i= S₁+ S₂+ ... + S_n… (Equation 4)
Ask for. Total E_nIs subtracted from the theoretical inventory amount G and divided by n to obtain the average value H of the daily production amount._n
H_n= (E_n-G) / n
Ask for. This is stored in a memory incorporated in the production schedule creation unit 100a in S306. This calculation is repeated until n reaches the leveling days D1. Therefore, when n is 1, the shipment quantity S on the first day (the first day of calculation allocation) of the period for which the production schedule plan is obtained is₁Is read from the storage unit 105, and E₁= S₁Is calculated, and the average value of the daily production amount H₁= (E₁-G) / 1 is determined and stored. Next, returning to S303, n becomes 2, and S₁Next working day S₂E of total shipment quantity up to₂= S₁+ S₂And the average value of daily production H₂= (E₂-G) / 2 is determined and stored. Next, n becomes 3 and S₂Next working day S₃E to be shipped until₃= S₁+ S₂+ S₃And the average value of daily production H₃= (E₃-G) / 3 is stored. Similarly, S304, S305, and S306 are repeated until n becomes the number of days D1 (S307). Thus, the average value H of the production amount of n = D1 pieces₁, H₂, H₃, ..., H_nIs selected, and the one having the largest value is selected from the values, and the value M to be assigned as the daily production amount of the product of the model K1 is selected.₁Is determined (S308). Since the production pattern P1 of the model K1 is a daily production, as shown in FIG.₁Is assigned to each operation day within the number of days D1 of the period for creating the production schedule plan (S309).
[0041]
On the other hand, a product (model K2) of the production pattern P2 (production three times a week), a product (model K3) of the production pattern P3 (production twice a week), and a product (model K4) of the production pattern P4 (production once a week) Determines the production volume according to the flow shown in FIG. First, in S400 of FIG. 7, for each product (models K2 to K4) of the production patterns P2 to P4, assuming that the production pattern is daily production, the same as S300 to S309 of FIG. 1. Determine the daily production volume and assign it to all operating days. Next, for each product (models K2 to K4), the allocated production amounts are totaled for each week, and the total production number Wsum per week is obtained (S400). Then, the production pattern is determined (S401, S404). Since the product (model K2) of the production pattern P2 is produced three times a week, a value M obtained by dividing the total number Wsum per week into three is M₂(S402), and this is sequentially allocated to three days from the beginning of the week of the corresponding week as shown in FIG. 9 as the daily production amount when the production is performed three times a week (S403). Specifically, if the working day of the week is five days from Monday to Friday, M₂, Thursday and Friday are assigned as 0.
[0042]
Since the product (model K3) of the production pattern P3 is produced twice a week, the value M obtained by dividing the total number Wsum per week into two is M₃(S405), and this is allocated to two days from the beginning of the week as shown in FIG. 9 (S406). Specifically, when the working day of the week is five days from Monday to Friday, Monday and Tuesday are M₃, 0 from Wednesday to Friday. Furthermore, in the case of the product (model K4) of the production pattern P4, since the production is performed once a week, the total number Wsum per week is not divided by the value M.₄(S407), and this is assigned to one day at the beginning of the week of the corresponding week as shown in FIG. 9 (S408). For example, if the working day of the week is five days from Monday to Friday, the production volume on Monday is M₄, From Tuesday to Friday.
[0043]
FIG. 8 shows a product (model K5) of the production pattern P5 (production three times a month), a product (model K6) of the production pattern P6 (production twice a month), and a product (model K7) of the production pattern P7. The production volume is determined by such a flow. First, daily shipment quantities S for the current month in the production schedule plan for each of the products K5 to K7._iIs read from the storage unit 105 of the shipping schedule creation system 103, the total shipping amount L1 for the current month is obtained, and the total shipping amount L2 for the next month is similarly obtained for the next month. (S500). The production pattern is determined (S501, S504), and for the product (model K5) of the production pattern P5, the total production amount L of the current month is obtained.₅₀To
L₅₀= (L1 × 2/3) + (L2 × 1/3) (Equation 5)
(S502). The production pattern P5 is produced three times a month.₅Is determined, and this is set as a single production amount, and as shown in FIG. 10, the relevant month is assigned to the last working day in a period obtained by dividing the month into three (S503). The method of dividing the month into three is based on working days. For example, 30 days production quantity M₅, 20 days production volume M₅, 10 days production volume M₅(See FIG. 10).
[0044]
On the other hand, for the product (model K6) of the production pattern P6 (produced twice a month), the total production amount L₆₀To
L₆₀= (L1 x 1/3) + (L2 x 2/3) (Equation 6)
(S505). The production pattern P6 is produced twice a month.₆Is determined as a single production amount, and as shown in FIG. 10, each is assigned to the last operating day of a period in which the relevant month is divided into two (S506). The method of dividing the month into two is based on the working day. For example, 30 days production volume M₆, Production volume on the 15th₆Assign
[0045]
Further, for the product (model K7) of the production pattern P7 (produced once a month), the total shipment amount L2 in the next month of S500 is calculated by the total production amount L of the current month.₇₀As
L₇₀= L2 (Equation 7)
(S507). The production pattern P7 is produced once a month.₇₀As it is, once a month production volume M₇As shown in FIG. 10, a work day at the end of the month is assigned (S508).
[0046]
As described above, when the daily production quantity allocation is determined for each of the production patterns P1 to P7 (S1103 in FIG. 3), this is stored (S1104). When the allocation of the production quantities has been completed for all the product types K1 to K7 of the products to be manufactured in the production line ML1 in S1101 to S1103, the production quantities of the allocated K1 to K7 are calculated on a daily basis. The total is calculated (S1106).
[0047]
As shown in FIG. 12, for example, the production quantity of the line ML1 summed for K1 to K7 greatly fluctuates every day. Therefore, the production quantities are leveled by the following S1107 to S1111. First, the difference between the maximum production amount and the minimum production amount among the daily production amounts in the period D1 is determined, and it is determined whether the difference (variation amount) is within a predetermined reference amount (S1107). If it exceeds, in S1108 and below, a leveling operation, that is, a landslide is performed to keep it within the reference amount. Although the reference amount can be arbitrarily determined, the production capacity of the corresponding production line MLx is read from the storage device 102a of the production-related master database 102 in FIG. And so on.
[0048]
In S1108 and S1109, first, the order n of the products (models K1 to K7) on which the landslide is performed is set, and n is incremented by one. In the present embodiment, as shown in FIG. 11, the landslide ranking and the method thereof correspond to the production patterns P1 to P7, the production pattern P1 with the lowest production frequency is set as the landslide ranking first, and the production is performed in order. The second to sixth ranks are determined in order from the least frequent to the production pattern P6. Regarding the production pattern P1 of daily production, the same production amount M is set in S309 of FIG.₁Is allocated every day and leveling has already been done, so no mountain landslides are performed. In addition, the direction of the landslide (movement of the production quantity) and the landslide range (the maximum movement range of the production amount) are determined as shown in FIG. 11 according to the production patterns P1 to P6.
[0049]
First, the production amount of the product (model K7) of the production pattern P7 (production once a month) in the hill-sloping rank 1 is moved and leveled (S1110 in FIG. 3). Production volume M of product with production pattern P7₇Is assigned to the last operating day at the end of the month, and is shifted one day before the previous day as shown in FIG. 12 (FIG. 12). At this time, the maximum movement range that can be shifted is called a landslide range, and in the case of the production amount of the product of the production pattern P7, it is one month ahead (the side that advances the production date) (FIG. 11). Production volume M₇Is shifted one day at a time to the maximum movement range (maximum landslide range), the difference between the maximum production quantity and the minimum production quantity among the daily production quantities is obtained, and the movement quantity at which this difference (variation amount) becomes the smallest is determined. And the position is the production volume M after the landslide₇Is the allocation date. Note that the production volume M₇If the amount of fluctuation does not become small even if is moved, the landslide is not performed and the position is returned to the original allocation position (the last operating day at the end of the month in the case of P7). Thus, the output M₇Of the production pattern P7 even if₇Is allocated at the end of the month M (1) so as to satisfy the shipping schedule of the following month, so that the shipping schedule is inevitably observed.
[0050]
After the collapse of the production pattern P7, it is determined in S1111 whether the difference (fluctuation amount) between the maximum production quantity and the minimum production quantity among the daily production quantities is within the reference value in S1107, and If not, the process returns to S1109, and the production amount M of the product (model K6) of the production pattern P6 in the second highest hillslide order₆Make a landslide. Production amount M of production pattern P6₆Are assigned to the last operation day of the half of the month, and as shown in FIG. The landslide range is 1/2 month as shown in FIG. 11, and the landslide direction is from the end of the month to the front side (the side that advances the production date). Also in this case, similarly to the above, the movement amount at which the fluctuation amount becomes the smallest is obtained, and the position is set to the production amount M after the collapse.₆Is the allocation date. Note that the production volume M₆If the amount of fluctuation does not become small even if is moved, the landslide is not performed, and the initial allocation position is maintained. Thus, the output M₆, The shipping schedule is inevitably complied with, as in the case of the landslide of the production pattern P7 described above.
[0051]
If the entire leveling has not been completed yet in S1111, the process returns to S1109, and the production amount M of the product (model K5) of the third-highest production pattern P5 is returned.₅In the same way. Production volume M₅Is assigned to the last working day of the third of the month, so shift it by one day to the previous day as shown in FIG. 14. The landslide range is 1/3 month as shown in FIG. The direction of the landslide is on the front side. Production volume M₅Is shifted forward within one-third of the month by M₅The arrangement does not cause any inconvenience and the shipping schedule is inevitably observed. If the variation does not become small even after the landslide, the initial allocation position is kept.
[0052]
If the overall leveling has not been completed in S1111, the production amount M of the product (model K4) of the fourth-ranking production pattern P4 is determined.₄In the same way. Production volume M₄Is assigned to the first working day of the week, so as shown in FIG.₄Is shifted by one day at a later date. The landslide direction is the side that shifts the production date backward, and the maximum landslide range is one week. Production volume M₄Is placed on the first working day of the week to satisfy the shipping schedule, so there is a risk that the shipping schedule will not be complied with if it is shifted backwards endlessly, but since the maximum landslide range is one week, the shipping schedule Can be protected.
[0053]
If the entire leveling is not completed in S1111 even then, the production amount M of the product (model K3) of the fifth-ranked production pattern P3 is next.₃In the same way. The landslide direction is the side that shifts the production date backward, and the maximum landslide range is one week.
[0054]
If the entire leveling has not been completed in S1111 as well, the production amount M of the product (model K2) of the last sixth production pattern P2 is obtained.₂Make a landslide. The landslide direction is the side that shifts the production date backward, and the maximum landslide range is one week.
[0055]
In S1111, if the last landslide of the sixth rank is completed (if n = 6 is reached) or if the variation is within the standard, the process proceeds to S1112, and daily production after the landslide is performed. The quantity is stored in the storage unit 100b as a production schedule.
[0056]
As described above, a leveled production schedule plan can be created for the production line ML1. Similarly, other production lines ML2, ML3,.
[0057]
FIG. 16 shows the production amount M of the product (model K4) of the production pattern P4.₄This shows a production schedule plan in which the variation was within a certain standard up to the collapse of the mountain. When commodities (models K1 to K7) are produced on the production line ML1 in accordance with the production schedule plan, the production is performed so that the production quantity corresponding to the production date assigned in the production schedule plan is completed as a finished product. Production is started on the production line ML1 ahead of the lead time. As a result, it is possible to produce finished products in a number that satisfies the shipping quantity of the shipping schedule plan.
[0058]
As described above, since the production schedule creation processing described with reference to FIGS. 3 to 16 can be performed by a computer system, the portion where humans intervene can be limited to confirmation of the result. Therefore, the process can be completed in a short time, and the period from the end of the creation of one production schedule to the end of the creation of the next production schedule, that is, the cycle of updating the production schedule can be shortened. As a result, the shipping schedule, shipping results, production results, and the like can be reflected in the production schedule plan in a more recent state.
[0059]
The cycle of the production schedule update can be set arbitrarily, for example, on a weekly basis or on a ten-day basis. For example, the update cycle is one week, and the production schedule plan creation range is (future) six months. In this case, as shown in FIG. 17, assuming that the production schedule plan creation date P (i) is in the N-month, the plan for N to N + May is created by the above-described production schedule creation process. As described above, for this six-month period, all daily plans (plans of daily production amounts) can be created. However, since it is sufficient to be able to grasp the approximate production amount in the future, FIG. As described above, a daily plan (daily production plan) is created as described above from N month to N + February, and only a monthly plan (monthly production plan) is created from N + March to N + May. You can also. This is because future plans are likely to be changed even if they are daily, and monthly plans are sufficient for long-term component procurement and workforce planning. On the other hand, if the latest production plan is changed, if the production quantity before the change is different from the production quantity after the change, it will not be possible to produce enough with the working hours scheduled before the change, and it will be necessary to urgently work overtime Due to the possibility, it is desirable not to change the production plan immediately before. Therefore, in the week following the production schedule creation date, it is desirable that the production quantity is defined as an area and the production quantity is fixed in principle (exceptions will be given later in case of changing). Then, after the next two weeks, it is desirable to set the undetermined area as an area for reflecting the change requested by the customer and to update the production schedule. Therefore, on the next production schedule plan creation date P (i + 1) one week after the production schedule plan creation date P (i), the next week after P (i + 1) is set as the schedule fixed area, and the subsequent weeks are the production week. A production schedule is created as a schedule update target. Further, when the production schedule plan creation date reaches the last week of N month, the production schedule plan from N + 1 month to N + June is created.
[0060]
Further, as described above, the movement grasping device 104 (FIG. 2) grasps the quantity movement. The quantity dynamics are the number of parts in the receiving part 104a (warehouse) of the purchased parts, the number of intermediate products and the number of finished products in the production line 104b, and the number of finished products in the product warehouse 104c. A quantity that changes every moment at a given point in the manufacturing process, such as every time a product arrives, every time a part is delivered from the parts warehouse to the assembly line, every time assembly is completed on the assembly line and each product is received in the product warehouse. Is received, or the quantity is detected and stored in the storage unit 104d.
[0061]
Further, the shipping schedule creation system 103 transfers the shipping quantity of the shipping schedule planning data to the product warehouse 104c, and instructs shipping. Further, the shipping schedule creation system 103 receives, from the storage unit 104d, quantity data information of the products shipped from the product warehouse 104c of the activity grasping device 104 as actual data. The shipping schedule creation unit 103a checks daily that shipping schedule plan data and shipping performance data are checked to ensure that there is no delay in the shipping schedule (S1113 in FIG. 3). In S1114, the shipping schedule creation system 103 receives the production schedule plan created by the production schedule creation system 100 and stored in S1112. Then, the daily shippable quantity for the latest fixed schedule (for the next week) is calculated by the following formula.
Available quantity = Current stock quantity in product warehouse 104c + Production quantity produced by shipment date−Shipment quantity shipped by shipment date
And compare it with the shipment quantity in the shipping schedule for that day. If the shippable quantity is smaller than the shipment quantity, it means that the product is out of stock. Therefore, a warning is issued from the shipment schedule creation system 103 to the production schedule creation system 100. In addition, a warning is issued to a manager of this production management system by a display unit or a sound generation unit (not shown) to notify the manager. The production schedule creation system 100 that has received the warning does not wait for the above-described update cycle (here, the update cycle is one week), and also satisfies the shipment plan in the plan confirmation area of the next week, as shown in FIG. The production schedule is updated according to the flow (FIG. 17). In addition, the difference between the quantity of the production schedule plan before the change for the fixed schedule and the quantity of the production schedule plan after the change is determined, and it is reported to the manager as an emergency additional production quantity, and it is necessary to make an emergency production change such as overtime work. That there is is notified (S1114).
[0062]
As described above, according to the production schedule management system 2000 of FIG. 2, the production is divided into patterns according to the shipment quantities of the products, and the calculation method of the production quantity is changed for each pattern, thereby leveling the workload of the manufacturing department. Can be Therefore, the production can be stably performed and the stock amount can be reduced. In addition, it is possible to check the dynamics and confirm that the daily shipping schedule is satisfied, and to issue a temporary work change instruction if necessary, thereby preventing a shipping delay. Further, since the production schedule quantity can be calculated and processed by a computer program, a schedule can be set in a short time and in a short period. This means that information necessary for schedule creation, such as customer product requirements, shipping results, and production results, can be taken in a newer form, and the system can easily adjust the stock amount.
[0063]
Next, the component delivery instruction system 106 will be described below.
[0064]
The parts delivery instruction system 106 includes a delivery instruction creation unit 106a, a delivery instruction data storage unit 106b, an order data creation unit 106c, an order data storage unit 106d, and storage units 10, 20, and 30 for storing part information. I have. The delivery instruction creating unit 106a and the order data creating unit 106c have a built-in memory and CPU, and operate as follows when the CPU reads and executes a program stored in advance in the memory.
[0065]
The delivery instruction creation unit 106a reads the production schedule plan created by the production schedule creation system 100 (FIG. 2) from the storage unit 100b (S600 in FIG. 18). Further, the parts necessary for producing the products to be produced (models K1 to K7) are read from the parts configuration master storage unit 10 (S601). Based on the read information, the number of parts (required amount) required to produce a product corresponding to the production amount of the production schedule plan is calculated for each component constituting the product (S602). Here, in accordance with the production schedule plan, the required amount is determined for each day for the due date close to the calculation processing date, and for the distant place, the total number of months is determined. For example, assuming that the calculation month is N-January, daily component requirements are calculated from N months to N + February, and monthly component requirements are calculated from N + March to N + May. This concept is shown in FIG.
[0066]
Next, the delivery instruction creating unit 106a refers to the order information master storage unit 20 (FIG. 2), acquires a predetermined order ratio of the parts supplier, and determines whether or not to perform the simultaneous ordering (ordering to two or more companies). It is determined whether or not (S603 in FIG. 18). Of the dozens or hundreds of business partners, co-injection is not limited to two, but here the case of two co-injection will be described. When it is stored in the ordering information master storage unit 20 that the same parts are purchased at the ratio of R1 and R2 (= 1−R1) respectively for the supplier A and the supplier B, the parts purchased from the supplier A are , As the number of parts used by Company A
Number of parts used = daily production quantity x total number of parts per product x R1
Is calculated (S604), and as for the parts from Company B, the number of parts used by Company B is calculated.
Number of parts used = daily production quantity x total number of parts per product x R2
Is obtained by calculation (S605).
[0067]
On the other hand, if the parts are not purchased together and purchased from only one company,
Number of parts used = daily production quantity x total number of parts per product
Is obtained by calculation (S606).
[0068]
When the daily number of parts used is determined, data is acquired from the parts procurement master storage unit 30, and the number of delivery instructions is calculated. The parts procurement master accumulates the actual amount of stock of each part and the set planned number of stocks through the movement grasping device 104. The number of delivery orders is calculated first as the total number of delivery orders for the week,
Total number of delivery instructions in Wn week = (Total number of parts used in Wn week) + (Number of stocks in Wn weekend weekend) − (Wn-1 Number of stocks in weekend weekend)
(S607), then the daily quantity
Number of daily delivery instructions in Wn week = (total number of delivery instructions in Wn week) / (working days in Wn week)
Is calculated (S608). Here, “Wn weekend stock quantity” means the planned stock quantity of the week.
[0069]
Next, the purchase of the delivered product will be described. Opportunities to deliver parts individually are small, and it is more practical to group them in a certain quantity unit, for example, to deliver in dozens of boxes or boxes of 20 pieces. This unit of quantity is called the minimum purchase unit. Therefore, the delivery instruction is also performed using the minimum purchase unit. Here, rounding calculation is performed to make the number of delivery instructions a multiple of the minimum purchase unit. The minimum purchase unit is a numerical value unique to the component, but is called from the component procurement master storage unit 30 registered in advance (S609). Taking into account the minimum purchase unit, the number of daily delivery instructions for the Wn week is calculated (S610). The calculation method is as follows.
Allocation days = total number of delivery instructions in Wn weeks / ((minimum purchase unit) x N)
And when
Working days ≧ allocation days
Find the smallest natural number N that satisfies_minfar. And
(Minimum purchase unit) × N_min
Is the number of delivery instructions per day,
Total number of delivery instructions in Wn week ÷ ((minimum purchase unit) × N_min)
Is the number of days assigned.
[0070]
Next, the category of the delivery cycle (delivery frequency) is called from the parts procurement master storage unit 30 (S611). The delivery frequency differs depending on various conditions such as the parts purchaser's condition, that is, geographical distance and the size of the transaction. For example, Company A has daily delivery flights because it is close to the factory and there is a large amount of transactions, whereas Company B is delivered once a week because it is distant and has small quantities. For this reason, a method of allocating the number of deliveries according to a delivery cycle predetermined for each supplier is adopted. The division of the delivery cycle is a convention and can be arbitrarily set (S612). Here, as an example, a case where the division is divided into four divisions of D0, W1, W2, and W3 will be described. This indicates that the delivery frequency is daily (D0), once a week (W1), twice a week (W2), and once every two weeks (W3).
[0071]
In the case of D0 parts, the order from the beginning of the week (minimum purchase unit) × N_minAre allocated until the total number of delivery instructions reaches the total number of delivery instructions in the Wn week (S613). Since the parts of W1 are once a week, (the minimum purchase unit) × N_minA quantity of “×” (number of allocation days) is allocated (S614). Here, in order to avoid that the delivery flights are concentrated on one day, the first working day or the second working day is set here. In addition, since the W2 part is twice a week, the combination of the first and third operating days or the second and fourth operating days (minimum purchase unit) × N_min× (number of allocation days) divided by 2 (S615). The distribution dates are dispersed for the same reason as W1. In the part of W3, (the total number of delivery instructions in the Wn week) + (the total number of delivery instructions in the Wn + 1 week) is assigned once every two weeks on the first operating day (S616). The delivery instruction data created in this way is stored in the storage unit 106b.
[0072]
The delivery instruction data created in this manner is information indicating which parts and how many parts are required in a certain time unit, for example, a daily unit and a monthly unit, and a communication control device (not shown) is used as an information transmission method. Thus, it can be delivered by electronic data transmission over a network.
[0073]
The delivery instruction creation unit 106a updates the delivery instruction information at regular intervals in conjunction with the update of the production schedule. As shown in FIG. 19B, for example, if the production schedule is created on the date P (i) of the Wn week, the delivery instruction is also created immediately on the same day P (i). The production schedule fixed area is a delivery instruction quantity fixed area that is not changed at the time of updating, based on the same concept as the delivery instruction. As a result, it is promised that the part will be picked up within the fixed area period (FIX @ ZONE). On the other hand, since the information outside the determined area can be used as the order planning information that goes ahead, procurement of components without delay can be promoted.
[0074]
After the delivery instruction creation unit 106a determines the number of delivery instructions and issues a delivery instruction, the order data creation unit 106c calculates the order quantity based on this. This procedure will be described with reference to FIG. The order data creation unit 106c reads the delivery instruction data for the parts corresponding to each business partner from the storage unit 106b (S700), and calculates the total number of delivery instructions from the first working day of the calculation month to the final day of the finalized delivery instruction (a). ) Is calculated (S701). Next, the number of parts actually delivered (delivery result data) is read from the storage unit 104d of the movement grasping device 104, and the total number of delivery results (b) from the first working day of the calculation month to the day before the calculation is obtained ( S702). Further, the data of the number of remaining orders is read, and the total number of remaining orders (c) up to the day before the calculation is calculated (S703). Using these, (number of orders) = (a)-(b)-(c)
Ask for. Only when the order number becomes a positive number, the order is placed as the order request number (S704). Here, the remaining order quantity data is quantity data that has been ordered but not yet delivered. The order information can be transmitted from a communication control unit (not shown) using electronic data transmission via a network, similarly to the delivery instruction information.
[0075]
As described above, according to the delivery instruction system 106 of the present embodiment, the delivery instruction quantity can be calculated and processed in a short time by the computer program according to the above-described algorithm, so that the latest production schedule plan can be reflected. In other words, it is possible to obtain the result of calculating the required component amount in synchronization with the latest production schedule and issue a delivery instruction to the supplier. In addition, it becomes possible to set the fixed area of the delivery instruction longer than before.
[0076]
Next, a description will be given of expanding the above contents to business partners.
FIG. 21 conceptually shows how the above technology is applied to a parts maker, which is a primary subcontractor of a car maker. A portion Q1 surrounded by a dotted line is a portion to which the present technology, that is, the “production schedule creation system 2000” and the “delivery instruction creation system 106” are applied. It can be applied to m-th subcontractors one after another, such as Q1 as the first stage and Q2 as the second stage (1 ≦ m ≦ n). Although the material maker (Qn), which is the last n-th subcontractor, cannot issue a delivery instruction, at least the production schedule creation system 2000 can be applied. As described above, when a car maker issues final information after issuing advance information, there is a quantitative shift, that is, a fluctuation between these pieces of information. Generally, the fluctuation amount increases as the downstream subcontractor becomes, but by applying the present technology, the fluctuation amount can be reduced at each stage. If this is repeated several times, it is sufficient that a certain m-order subcontractor is always producing a fixed amount of delivered goods every day or every hour.
[0077]
In addition, if this system is introduced as a system, information can be linked between companies, and information can be shared between two or more distant companies. For example, the following situation can be considered. It is not known how many m-subcontractor material manufacturers (here m> 2) usually produce cars this month or how much demand they have placed on subcontractors. Here, when this system is introduced, two or more distant companies can share information with each other as described above, and as a result, it is possible to understand the production preparation status mutually, Can be performed more quickly.
[0078]
As described above, if this system is introduced as a series, it will benefit both the automobile manufacturer and each subcontractor.
[0079]
The above-described production management system 2000 and delivery instruction system 106 are for managing the production of the production line MLx of the company. It is also possible to run a business that supports the production management of other companies that have received a management request and receives a fee as compensation. In this case, the other company receives the advance notice information N (i), the correction information W (i), and the fixed information D (i) received from the customer, and processes the received information by the production management system 2000. A schedule plan and a production schedule plan are created, and the created shipment schedule plan and production schedule plan are transmitted to the other company by a communication control device or the like. As a result, the other company can stably perform production with a small inventory amount and a standardized production plan. In this case, in the production-related master database 102, data of the contracted production line of the other company is stored in advance, and a receiving unit or a detecting unit that receives the input of the quantity of the dynamic state grasping device 104 is It is desirable to arrange in a production line 104b, a product warehouse 104c, or the like, and to receive quantity data via a network or the like. Similarly, in addition to the shipping schedule plan and the production schedule plan, a delivery instruction can be created by the delivery instruction system 106, and the delivery instruction data and the order data can be transmitted to the parts maker on behalf of the other company.
[0080]
In the production management system 2000 according to the present embodiment, since a product to be produced is a product called a production product, the customer is not a general consumer, but is provided with the product, and is further processed and processed. The manufacturing industry in which the assembly was performed, such as a car maker. However, the production management system 2000 according to the present embodiment is a product called a consumer product (a product of a type in which the company predicts demand and determines the production amount. It can also be applied to the production management of cosmetics that have been seen).
[0081]
According to the above-described production management system 2000 of the present embodiment, a production plan is prepared in which the amount of work is leveled in response to customer's product request information, a production instruction is issued, and delivery of procured parts necessary for production is performed. The effect is obtained that the instruction can be provided to the purchaser in consideration of the physical quantity determination area and the schedule information of several months. In addition, it is possible to deliver products to customers as required while keeping the stocks of the products and components appropriate, and transactions with the suppliers of the components can proceed smoothly.
[0082]
【The invention's effect】
According to the present invention, it is possible to create a production schedule in which the production amount is leveled. Further, it is possible to provide a production schedule creation system capable of creating such a production schedule.
[Brief description of the drawings]
FIG. 1 is an explanatory diagram for explaining a conventional relationship between a time for manufacturing a product on a production side, a time for receiving a delivery instruction from a customer, and a time for delivering a product to a customer.
FIG. 2 is a block diagram showing a configuration of a production management system 2000 and a delivery instruction system 106 according to an embodiment of the present invention.
FIG. 3 is a flowchart showing an operation of the production management system 2000 according to one embodiment of the present invention.
FIG. 4 is an explanatory diagram showing a daily variation of the shipment quantity obtained by the production management system 2000 according to the embodiment of the present invention and a tendency of the shipment quantity of the product.
FIG. 5 is a flowchart showing an operation of the production management system 2000 according to one embodiment of the present invention.
FIG. 6 is a flowchart showing an operation of the production management system 2000 according to one embodiment of the present invention.
FIG. 7 is a flowchart showing an operation of the production management system 2000 according to one embodiment of the present invention.
FIG. 8 is a flowchart showing an operation of the production management system 2000 according to one embodiment of the present invention.
FIG. 9 is an explanatory diagram for explaining a production quantity allocated to each production pattern by the operation of FIGS. 6 and 7 in the production management system 2000 according to the embodiment of the present invention.
FIG. 10 is an explanatory diagram for explaining a production quantity allocated to each production pattern by the operation of FIG. 8 in the production management system 2000 according to one embodiment of the present invention.
FIG. 11 is an explanatory diagram showing a relationship between a production pattern and a ranking of a production quantity leveling process, which is also used in a production schedule creation procedure, in the production management system 2000 according to the embodiment of the present invention. is there.
FIG. 12 is an explanatory diagram for describing a production quantity leveling process in the production management system 2000 according to the embodiment of the present invention.
FIG. 13 is an explanatory diagram for describing a production quantity leveling process in the production management system 2000 according to the embodiment of the present invention.
FIG. 14 is an explanatory diagram for describing a production quantity leveling process in the production management system 2000 according to the embodiment of the present invention.
FIG. 15 is an explanatory diagram for describing a production quantity leveling process in the production management system 2000 according to the embodiment of the present invention.
FIG. 16 is an explanatory diagram showing an example of a result after a production quantity leveling process in the production management system 2000 according to the embodiment of the present invention.
FIG. 17 is an explanatory diagram for explaining a creation (update) timing and a creation period of a production schedule plan created by the production management system 2000 according to the embodiment of the present invention.
FIG. 18 is a flowchart for creating a procedure for creating a delivery instruction based on the production schedule plan created by the production schedule creation system in the delivery instruction system according to one embodiment of the present invention; It is.
FIG. 19A is an explanatory diagram showing a relationship between a delivery instruction created in a delivery instruction system according to an embodiment of the present invention and a production schedule, and FIG. It is explanatory drawing for demonstrating the timing of delivery instruction preparation, and preparation range.
FIG. 20 is a flowchart illustrating a procedure for obtaining an order quantity based on the created number of delivery instructions in the delivery instruction system according to one embodiment of the present invention.
FIG. 20 is a block diagram showing a case in which the production schedule creation system and the delivery instruction system according to one embodiment of the present invention are sequentially applied to an nth-order subcontractor.
[Explanation of symbols]
Reference Signs List 10: parts configuration master storage unit, 20: order information master storage unit, 30: parts procurement master storage unit, 100: production schedule creation system, 100a: production schedule creation unit, 100b: production schedule data storage unit, 101: order information Collection unit, 101a, 101b, 101c: memory, 102: production related master database, 102a, 102b, 102c: storage device, 103: shipping schedule creation system, 103a: shipping schedule creation unit, 104: dynamic grasping device, 104a: receiving Unit, 104b: production line, 104c: product warehouse, 104d: quantity grasp database storage unit, 105: shipment schedule planning data storage unit, 106: delivery instruction system, 106a: delivery instruction creation unit, 106b: delivery instruction data storage unit, 106c: order data creation unit, 106d: order data storage unit, 20 0 ... production management system, 2001 ... customer.

Claims (15)

We categorize online customer demand into multiple pieces based on the number of products produced,
Determine the production frequency based on the classification,
A production schedule creation method for creating a production schedule for producing a predetermined quantity at the production frequency. A production schedule creation system for creating a production schedule plan for a production line capable of manufacturing a plurality of types of products,
For a plurality of types of products, a storage unit that stores information indicating the number of delivery and delivery date received from a customer,
A production frequency determining means for determining a total of the number of deliveries for a predetermined period for each of the plurality of types of products, and determining a predetermined production frequency for each type of the product according to the magnitude of the total of the number of deliveries; and ,
At the production frequency determined by the production frequency determination means, in order to produce the total of the number of deliveries for the predetermined period, the number of products to be produced in one production is obtained for each type of the product, A production schedule determining means for creating a production schedule plan by allocating the number of articles to be produced as the number of products to be produced on the production date selected by the production frequency on the production line,
The total of the production numbers for the plurality of types of products assigned by the production schedule determination means is obtained for each of the working days, and if the variation in the obtained total of the production numbers is larger than a predetermined reference value, the production Leveling means for moving the production quantity assigned by the production schedule determining means to another operation day in order from the product having the least production frequency determined by the frequency determining means, and leveling the production schedule plan And a production schedule creation system. The production schedule creation system according to claim 2, wherein the leveling unit determines whether a direction in which the number of products to be produced is moved in the another operation day, which is predetermined for each production frequency, is a forward direction or a backward direction. A production schedule creation system, which stores information indicating a maximum range in which the movement is allowed and information indicating the maximum range in which the movement is permitted, and performs the movement according to the stored direction and the maximum range. The production schedule creation system according to claim 2, wherein the delivery number and the delivery date are read from the storage unit, and the date when the delivery date is advanced by a predetermined time required for transportation is set as a shipping date. A production schedule creation system, further comprising a shipment schedule creation means for creating a shipment schedule by assigning the delivery quantity to the shipment date. The production schedule creation system according to claim 4, further comprising a monitoring unit,
The shipping schedule creation means, when there is a change in the number of delivery and delivery date from the customer, changes the shipping schedule plan accordingly,
The monitoring means, when the shipping schedule is changed, the number of deliveries on the shipping date of the changed shipping schedule, and the number of products to be produced by the shipping date according to the production schedule. And producing an alarm if the production quantity is smaller than the delivery quantity. 6. The production schedule creation system according to claim 5, wherein, when the warning is output, the monitoring unit sends the production frequency determination unit, the production schedule determination unit, and the leveling unit after the change. A production schedule creation system, wherein the production schedule corresponding to the delivery quantity and the delivery date is recreated. 3. The production schedule creation system according to claim 2, wherein a stock amount storage unit that sequentially stores information on stock quantities of the plurality of types of products in a product warehouse that accommodates the plurality of types of products produced on the production line until shipment. 4. Further having
The production schedule determination system, wherein the production schedule determination means obtains the number of commodities to be produced from a value obtained by subtracting the stock quantity from the total of the delivery quantities. A production schedule creation system for creating a production schedule plan for a production line capable of manufacturing a plurality of types of products,
An order information collection unit that stores information indicating the number of deliveries and the date of delivery received from a customer for the plurality of types of products,
By receiving the number of deliveries and the delivery date from the order information collection unit, and setting the delivery date as a shipping date with a date advanced by a predetermined time required for transportation, and allocating the delivery quantity on the shipping date A shipping schedule creation unit that creates a shipping schedule and stores it;
A dynamic grasping unit that sequentially receives and stores the data of the inventory amount of the product warehouse,
A production line information storage unit for storing an operation day calendar of the production line,
A production schedule creation unit that receives the shipment schedule plan and the working day calendar and the stock amount data, and creates a production schedule plan;
The production schedule creation unit,
The total of the number of deliveries for a predetermined period of the shipping schedule plan is obtained for each of the plurality of types of products, and a predetermined production frequency is determined for each type of the product based on the magnitude of the total of the number of deliveries. Means for determining production frequency;
At the production frequency determined by the production frequency determining means, in order to produce the number of the products obtained by subtracting the stock amount from the total number of the delivered items in the predetermined period, the products to be produced in one production. Production schedule determination means for determining the number of products for each type of product, and assigning the number of products to be produced as the number of products to be produced as the number of products to be produced on the production day selected by the production frequency with the operation day of the calendar, and producing a production schedule plan. When,
The total of the production numbers for the plurality of types of products assigned by the production schedule determination means is obtained for each of the working days, and if the variation in the obtained total of the production numbers is larger than a predetermined reference value, the production Leveling means for moving the production quantity assigned by the production schedule determining means to another operation day in order from the product having the least production frequency determined by the frequency determining means, and leveling the production schedule plan And a production schedule creation system. The production schedule creation system according to claim 8, further comprising a monitoring unit,
The shipping schedule creation unit, when the order information collection unit receives information indicating a change in the number of deliveries and the delivery date from the customer, changes the shipping schedule plan accordingly,
The monitoring means, when the shipping schedule is changed, the number of deliveries on the shipping date of the changed shipping schedule, and the number of products to be produced by the shipping date according to the production schedule. A production schedule creation system characterized by outputting an alarm when the production quantity is smaller than the delivery quantity. A production schedule creation method for creating a production schedule plan of a production line capable of manufacturing a plurality of types of products,
For the plurality of types of products, based on data indicating the number of deliveries and the delivery date requested by the customer, a date when the delivery date is advanced by a time required for predetermined transportation is set as a shipping date, and the shipping date is set as the shipping date. Create a shipping schedule by assigning the number of deliveries,
The total of the number of deliveries for a predetermined period of the shipping schedule plan is obtained for each of the plurality of types of products, and a predetermined production frequency is determined for each type of the products based on the magnitude of the total of the number of deliveries. ,
At the determined production frequency, in order to produce the total of the number of deliveries for the predetermined period, the number of commodities to be produced in one production is obtained for each type of the commodities, and the operation day of the production line is determined. A production schedule is created by allocating the number of products to be produced as the number of products to be produced on the production date selected at the production frequency,
The total of the production numbers for the plurality of types of products is obtained for each of the working days, and when the obtained variation amount of the total of the production numbers is larger than a predetermined reference value, in order from the products with the lowest production frequency, A production schedule creation method, wherein the production quantity assigned to a production date is moved to another operation day, and the production schedule plan is leveled. The production schedule creation method according to claim 10,
If the customer has changed the delivery quantity and delivery date, change the shipping schedule accordingly,
Compared with the delivery quantity of the shipment date of the shipment schedule plan after the change, and the production quantity produced by the production schedule by the shipment date, if the production quantity is smaller than the delivery quantity, A production schedule creation method characterized by outputting an alarm. A method for supporting a manufacturer having a production line capable of producing a plurality of types of products to create a production schedule plan,
For the plurality of types of products, receiving data indicating the number of delivery and delivery date requested by the customer via the communication control device,
By receiving the number of deliveries and the delivery date from the order information collection unit, and setting the delivery date as a shipping date with a date advanced by a predetermined time required for transportation, and allocating the delivery quantity on the shipping date Create a shipping schedule,
The total of the number of deliveries for a predetermined period of the shipping schedule plan is obtained for each of the plurality of types of products, and a predetermined production frequency is determined for each type of the products based on the magnitude of the total of the number of deliveries. ,
At the determined production frequency, in order to produce the total of the number of deliveries for the predetermined period, the number of commodities to be produced in one production is obtained for each type of the commodities, and the operation day of the production line is determined. A production schedule is created by allocating the number of products to be produced as the number of products to be produced on the production date selected at the production frequency,
The total of the production numbers for the plurality of types of products is obtained for each of the working days, and when the obtained variation amount of the total of the production numbers is larger than a predetermined reference value, in order from the products with the lowest production frequency, Move the production quantity allocated to the production day to another working day, level the production schedule,
A production schedule plan creation supporting method, wherein the shipment schedule plan data and the leveled production schedule plan data are transmitted to the manufacturer via the communication control device. The production schedule planning support method according to claim 12,
If the customer receives data to change for the delivery quantity and delivery date, change the shipping schedule accordingly,
Compared with the delivery quantity of the shipment date of the shipment schedule plan after the change, and the production quantity produced by the production schedule by the shipment date, if the production quantity is smaller than the delivery quantity, A method for supporting production schedule planning, wherein an alarm is output to the manufacturer. For a production line capable of manufacturing a plurality of types of products, a production schedule plan storage unit that receives and stores a production schedule plan that defines a relationship between a production date and a production quantity created in advance,
For each of the plurality of products, a component information storage unit that stores the type and number of components required for manufacturing,
A stock amount collection unit for sequentially receiving and storing data of the stock amount of the parts,
Having a parts delivery instruction plan creating unit that creates a plan instructing to deliver the parts to an external parts maker,
The part delivery instruction plan creation unit obtains the number of the parts necessary for producing the production quantity of the production schedule plan for each type of the parts from the information of the part information storage unit, By setting the delivery date to be delivered up to the production date to the number of parts delivered minus the number of stocks from the number of parts, a parts delivery instruction plan is created and transmitted to an external parts manufacturer via the communication control device A parts delivery instruction system characterized by the following. The parts delivery instruction system according to claim 14, further comprising a production schedule creation system for creating the production schedule plan, wherein the production schedule creation system is the production schedule creation system according to claim 1. Parts delivery instruction system.

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