JP2004326268A - Production schedule creation method and its system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a blank layout production plan creation method and a system for it capable of improving the production yield and productivity during the blank layout in an original blank for a door material matching an ordered product. <P>SOLUTION: A first plan creation means 15a repeats layout in the original blank and cutting of the door material according to the plank layout priority of a door product number for the product number of a door required for production, and when the length of the residual part of the original blank becomes shorter than the length of a door material necessary for production, selects a door product number allowed for blank layout on the basis of computed demand priority and creates a blank layout plan. When cutting the door materials of all the product numbers required for production is finished, a second plan creation means 15b selects a product number allowed for blank layout according to the integration of blank layout plans or priority shown by the demand priority information for the original blank longer than a predetermined length and creates a second blank layout plan in which the door material of the product number allowed for blank layout is treated as a door material of free stock. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【００３８】
この場合は、
標準品番Ａ月平均需要＝ ［（７＋３３＋０）×（１．０＋α）＋（２０＋１００＋３）×（１．０＋β）＋（１４＋１１０＋２）］／３
需要指数＝（２０＋１００＋３）×ｙ＋（１４＋１１０＋２）×ｚ
となる。但し変数部分（α，β，ｙ，ｚ）の設定により当月及び前月の需要状況の重み付けを行う。また扉長さとは扉材の高さ方向の長さを示す。また原板幅を板取りを行う扉材の幅と同等の寸法のものとする。
【００３９】
このようにして各標準品番の需要優先度（需要指数）を算出することにより、常に製品の需要量に連動した優先管理を可能とし、また当月、漸減の需要量に対して重み付けによる補正を行うことで、直近の需要傾向を高く反映した需要優先度の管理を可能として、精度高い優先度管理を行う。
【００４０】
ところで、販売月数が所定月数（Ｎヶ月）に満たない製品については、前月の需要傾向に対して所定の補正を加えた月平均需要量を算出し、需要優先度（需要指数）を算出する。
【００４１】
表２は、扉品番Ａが所定月数（３ヶ月）に満たない場合の例を示す。
【００４２】
【表２】

【００４３】
この場合は、
標準品番Ａ月平均需要＝ （１５×（１．０＋γ）＋（３３＋０）×（１．０＋α）＋（１００＋３）×（１．０＋β）／３
需要指数＝１５×ｗ＋（１００＋３）×ｙ＋（１１０＋２）×ｚ
となる。但し変数部分（γ，ｗ）の設定により前月の需要状況の重み付けを行う。
【００４４】
このように販売月数が不足し、所定の期間の平均需要量が算出できない商品に対しては、前月の出庫量を基に平均需要量を換算することにより、他の製品と同様に需要優先度を評価できるのである。
【００４５】
以上のように需要優先度算出手段１１で算出した需要優先度は板取計画自動作成部１４へ渡される。
【００４６】
一方生産必要数算出手段１２は、注文情報データベースＤ１３に格納している注文情報及び在庫情報データベースＤ１４に格納している在庫情報とに基づいて、所定期間の扉品番毎の注文数と現在庫数（一般在庫）、下限在庫数を基に、生産に必要な扉数を算出する処理を行う。
【００４７】
この場合、
必要数（標準品番としての必要数）＝当日注文数＋注文数合計−（一般在庫合計−下限在庫合計）と計算する。
【００４８】
表３で示すような在庫情報・注文情報を基に、標準品番（１１０００９２１４６９００）について必要素数を上記式に当てはめると、当日（２００３／０１／２４）の注文数が６＋１で注文合計数が１２で、一般在庫合計数が１６、下限在庫合計数が２であるので、１＋６＋１２−（１６−２）＝５と必要数が求まることになる。
【００４９】
【表３】

【００５０】
このようにして生産必要数算出手段１２は、当日の注文数に加えて、現在庫合計（一般在庫）と、下限在庫合計、注文数総合計（注文未出荷品）を考慮し、生産必要数を決定することにより、納期変更による出荷延期品やクレーム督促などによる在庫品の予定外の出庫による在庫状況の変動にも対応した当日生産必要数の算出を行うことを可能とする。
【００５１】
さて上述のように算出された生産必要数は板取計画自動作成部１４へ渡される。
【００５２】
次に原板からの板取計画を作成するのであるが、板取計画自動作成部１４は最終的な板取計画を行う前に、第１，第２の計画作成手段１５ａ、１５ｂにおいて第１，第２の板取計画を立案作成する。
【００５３】
第１の板取計画の立案作成する第１の計画作成手段１５ａは、生産が必要な扉品番を対象に、扉品番の板取り優先順に原板の引き当てと、扉材の板取りとを繰り返して行い、原板の残り部位の長さが、生産に必要な扉材の長さよりも短く成った際に、上述で算出した需要優先度に基づいて板取り可能な扉品番を選定して板取りを行う計画を立案するのである。尚原板は定尺で、その幅が板取り対象の扉材の幅と同じのものが引き当てられ、原板の長手方向に扉材の高さ方向を併せて板取りが行われる。
【００５４】
つまり図２に示すようにまず生産オーダー（生産注文）の抽出処理Ｓ１として、板取りのための原板の品番の昇順、扉材の幅寸法の降順、扉材の長さの降順、扉品番の昇順を抽出する処理を行い、生産オーダー（生産注文）がある（Ｓ２）と、構成マスタ検索処理Ｓ３として扉品番に対する構成検索を品番マスタに対して行い、原板品番を抽出する。
【００５５】
原板品番を抽出すると、次に板取りのための原板在庫引き当て処理を行う処理Ｓ４を行い、更に製品たる扉品番に対応する扉材の板取計画割り付け処理、つまり扉品番板取計画割り付け処理Ｓ５を行う。
【００５６】
この扉品番板取計画割り付け処理Ｓ５を複数の例によって説明する。
【００５７】
（例１）
本例では、扉材の長さ寸法の長いものから板取り優先順位を定めたものである。例えば扉幅が同じであるが、図３（ａ）に示すように扉材の長さが品番Ａ乃至Ｄの順で短く、品番Ａの扉材の必要数が７枚、品番Ｂの扉材の必要数が５枚、品番Ｃの扉材の必要数が４枚、品番Ｄの扉材の必要数が３枚であるとすると、まず図３（ｂ）に示すように対応する幅の定尺の原板１００を引き当て、この原板１００に対して最も長い品番Ａの扉材を板取り可能な枚数（図示例では４枚）の板取りを割り当て、その残り部位に対して板取り可能な長さの品番の扉材を割り当てる。この場合最も短い品番Ｄの扉の扉材を割り当てることにことになる。
【００５８】
図３（ｃ）に示すように次の原板１００を引き当てて、該原板１００に対して品番Ａの扉の必要数の残り分（３枚分）の板取りを割り当て、その残り部位に対して板取り可能な長さの品番の扉材を割り当てる。この場合、長さが品番Ａのものに次いで長い品番Ｂの扉材を２枚分割り当てる。
【００５９】
更に次いで図３（ｄ）に示すように次の原板１００を引き当てて、該原板１００に対して品番Ｂの扉の必要数の残り分（３枚分）の板取りを割り当て、その残り部位に対して板取り可能な長さの品番の扉材を割り当てる。この場合、長さが品番Ｂのものに次いで長い品番Ｃの扉材の２枚分と品番Ｄの扉の扉材の１枚分を割り当てる。
【００６０】
そして更に図３（ｅ）に示すように次の原板１００を引き当てて、該原板１００に対して品番Ｃの扉の必要数の残り分（２枚分）の板取りを割り当て、その残り部位に対して板取り可能な長さの品番の扉材を割り当てる。この場合、長さが品番Ｄの残り１枚分の板取りを割り当てることができるとともに、更に余った残り部位に、需要優先度の順位に基づいて選定されたフリー在庫の優先順位の最も高い品番Ｘの扉材を板取り可能枚数分（図示例では４枚）割り当てる。
【００６１】
このようにして本例では扉材の長さ順に、原板引き当てと板取りを繰り返す第１の板取計画を立案作成するのである。
【００６２】
つまり、図２の扉品番板取計画割付処理Ｓ５で扉材を原板１００に割り付け、余り（残り部位）の長さが所定長さ以上（つまり扉材の板取りが可能な長さがあるのか否か）あるか否かを次の過程Ｓ６で判定し、長さが所定長さ以上あれば生産オーダー抽出処理Ｓ７で上記Ｓ１と同様な抽出処理を行い、生産オーダーがあれば（Ｓ８）、原板の余り（残り部位）の長さ未満の長さの扉材の品番が抽出されるまで図２における処理Ｓ６〜Ｓ９の処理を繰り返し、対応する品番が抽出されると、余り（残り部位）に対して対応する品番の扉材の板取りを割り付ける処理を行う（Ｓ１０）。
【００６３】
このように本例では、扉材の高さ方向の長いものから順に板取りを行うことにより、短時間での板取計画の作成が可能となり、また扉材の高さ方向の長さが長い品番の扉から順に板取りを行い、そのときの原板１００の余りの長さを、フリー在庫の扉材の生産を最小限にするような長さとすることで、歩留まりを高めた板取計画の作成が実現できる。
【００６４】
（例２）
例１では原板１００から板取りを行う優先順位を扉材の長さ順位によって決めていたが、本例では、生産が必要な枚数の多い順に優先順位を決めた点に特徴がある。
【００６５】
例えば図４（ａ）に示すように扉材の長さが品番Ａ乃至Ｄの順で短く、品番Ａの扉材の必要数が７枚、品番Ｂの扉材の必要数が５枚、品番Ｃの扉材の必要数が４枚、品番Ｄの扉材の必要数が３枚となった場合には、まず例１と同様な原板１００を最も必要数の多い品番Ｂの扉材に引き当てる。この場合１枚の原板１００からは品番Ｂの扉材が４枚分板取りできるため、品番Ｂの扉材の必要数を板取りするために３枚の原板１００を図４（ｂ）にように引き当てる。そして２枚の原板１００には４枚分の扉材の板取りを割り当てるとともに、各残りの部位には、当該部位の長さより短く、且つ需要優先度に基づいたフリー在庫優先順位が高い品番、例えば品番Ｘの扉材の板取りを割り当てる。そして品番Ｂに対応する３枚の扉材の板取りが割り当てられる最後の原板１００の残りの部位の長さは、次に必要数の多い品番Ａの扉材の長さよりも十分に長いため、残りの部位に品番Ａの扉材の板取りを割り当てる。この場合品番Ａの扉材が１枚板取りできることになる。そして更に残った部位は扉材を板取りすることができない余剰部分ａとなる。
【００６６】
次に品番Ａの扉材の板取りに対応して２枚の原板１００を引き当てる。この場合１枚の原板１００からは図４（ｃ）に示すように４枚の扉材が板取りができ、品番Ａの４枚の扉材の板取りを割り当てた場合の残りの部位の長さは品番Ｄの扉材を１枚板取りできる長さに対応するため、残り部位には品番Ｄの扉材の板取りを割り当てる。そして品番Ａの２枚の扉材の板取りを割り当てた原板１００の残りの部位の長さは、次に必要数の多い品番Ｃの扉材を３枚板取り可能なため、まず３枚の品番Ｃの扉材の板取りを割り当てる。そして残り部位に対しては需要優先度に基づくフリー在庫優先順が高く、残り部位から板取り可能な長さの品番、例えば品番Ｘの扉材の板取りを割り付ける。
【００６７】
さて必要数が４枚の品番Ｃの扉材は、既に上述のように３枚の板取り割り付けが終わっているため、残り１枚分の板取りを割り当てるために図４（ｄ）に示すように１枚の原板１００を引き当て、該原板１００に品番Ｃの扉材の１枚分の板取りを割り付ける。そして原板１００の残りの部位の長さが十分長いため、必要数が３枚で、既に１枚分の板取りが割り付けられている品番Ｄの扉材の残り２枚分を割り付ける。そして更に生じる残り部位に対しては需要優先度に基づくフリー在庫優先順が高く、残り部位から板取り可能な長さの品番、例えば品番Ｘの扉材の４枚分の板取りを割り付ける。そして最後に残った部位の長さに対応する品番の扉材が存在しないため、最後の残り部位は余剰部分ｂとなる。
【００６８】
このように本例では必要数が多い品番の扉材から優先順位を付けて板取りを行うことによって、同一品番によるロット生産（まとめ切断）が可能な板取計画を多く作成することが可能になり、生産性を高めた板取計画の作成が実現できる。
【００６９】
次に、上記の例１，２において、原板１００の残り部位にフリー在庫の扉材の板取りを割り付ける場合の、フリー在庫の選定順位の決定方法の例について説明する。
【００７０】
（例Ｉ）
本例では、第１の計画作成手段１５ａが行う板取計画割り付け処理において、生産に必要な全ての品番の扉材の長さよりも、原板１００の残り部位（余り部位）の長さが短くなり、かつ長さが最短の扉材以上（所定長さ以上）となると（図５のＳ１）、フリー在庫扉抽出処理Ｓ２に移行し、この在庫扉抽出処理Ｓ２では、第１の計画作成手段１５ａにおいて、在庫情報データベースＤ１４からの情報に基づいて、フリー在庫数［＝（現在庫数−注文引当在庫−下限在庫）］の在庫日数［＝（フリー在庫数／月平均順需要量）］を求め、フリー在庫としての選定順位（フリー在庫に日数の昇順）を決定する。
【００７１】
そして第１の計画作成手段１５ａでは選定順位に基づいてフリー在庫の品番の有無をチェックし（Ｓ３）、品番があると原板１００の残り部位（余り部位）の長さと、当該品番の扉材とを比較し（Ｓ４）、扉材の長さが残り部位の長さ未満の場合には、フリー在庫品番の扉材の板取計画割り付け処理（Ｓ５）を上述の例１又は２のように行うのである。扉材の長さが残り部位の長さを超える場合には、Ｓ１へ戻る。また原板１００の残り部位（余り部位）の長さが所定長さ未満の場合や、フリー在庫の品番のチェックで品番が無ければ当該原板１００に対する板取りを終了する。
【００７２】
（例ＩＩ）
本例は、フリー在庫に対応する板取りを行う対象品番のフリー在庫日数が予め定めている所定の基準日数を超えている場合には、フリー在庫として板取りを行わないようにする例で、月平均の需要量に応じた一定の在庫日数による運用管理が可能となり、フリー在庫が生産過剰となるのを抑制することが可能となる。
【００７３】
図６は本例のフリー在庫の板取りのフローチャートを示しており、図示例では図５のフローチャートにフリー在庫日数のチェック（Ｓ６）を加えている。
【００７４】
（例ＩＩＩ）
本例は例ＩＩの上記在庫日数の代わりに、フリー在庫数が予め定めている基準数を超えた場合には、フリー在庫として板取りを行わないようにする例で、月平均の需要量が非常に大きくためにフリー在庫日数が小さくなる品番のフリー在庫数の絶対量が大きくなるのを防ぐことが可能となり、そのため製品を保管する在庫スペースを一定量以内に保つことが可能となる。
【００７５】
（例ＩＶ）
図７は本例のフリー在庫のフローチャートを示しており、図示例では図５のフローチャートに、フリー在庫数のチェック（Ｓ７）を加えている。
【００７６】
上記例Ｉ〜ｃでは、フリー在庫の品番の扉材に対する板取りは、フリー在庫の日数（昇順）で選定された優先順位に沿って行っているが、このような場合扉材の高さ方向の長い扉は、フリー在庫として板取りされにくくなる。そこで本例では予め特定のフリー在庫対象品番を定め、原板１００の残り部位（余り部位）の長さが生産に必要な全ての扉材の高さ方向のよりも短くなった際に、まず特定のフリー在庫対象品番を最優先して板取りを行うことで、特定の品番に対するフリー在庫を増やすことを可能とした。
【００７７】
図８は本例の場合のフリー在庫の板取りのフローチャートを示しており、この図示例では、図７のフローチャートに上述の特定品番でのフリー在庫の可否のチェックＳ８と、フリー在庫が可能な場合のフリー在庫扉品番板取計画割り付け処理Ｓ９を加えている。
【００７８】
而して上述した例Ｉ〜例ＩＩＩの何れかのフリー在庫の板取り方法を例１又は例２の板取計画割り付け方法を用いて第１の計画作成手段１５ａにより第１の板取計画が作成され、この作成された第１の板取計画は、第１の板取計画結果格納データベースＤ１５ａに格納される。
【００７９】
次に第２の計画作成手段１５ｂによる第２の板取計画の立案作成について説明する。
【００８０】
まず第２の計画作成手段１５ｂは、生産が必要な品番の扉材を対象に、１品番毎に原板１００を引き当て、扉材の板取りを繰り返して行い、生産を必要とする全ての品番の扉材に対する板取りが終了した後、残り部位（余り部位）の長さが、所定の長さより長い原板１００に対して、板取計画の統合又は上述の需要優先度情報が示す優先度順に従って板取り可能な品番を選定し、該品番の扉材をフリー在庫の扉材として板取計画を第２の板取計画として立案する。
【００８１】
次にこの第２の計画作成手段１５ｂでの板取計画方法を複数の例によって説明する。
【００８２】
（例ｉ）
本例の第２の計画作成手段１５ｂは、生産を必要とする全ての品番の扉材に対する必要な枚数の板取りが終了した後、同一の板取りパターンの原板の数が予め定めた所定枚数以上の場合には、同一の板取りパターンとならなかった原板の残り部位（余り部位）に対して上記品番Ａの扉材に対する板取りを行って、当該原板の板取りパターンを他の原板と同じ板取りパターンとする板取計画を立案作成する。
【００８３】
例えば品番Ａの扉材を２６枚必要とする場合、品番Ａの扉材を４枚板取りできる原板１００を用いると、図９（ａ）に示すように７枚の原板１００を引き当てる必要がある。そしてこの場合同一の板取りパターンの原板１００の枚数は図示するように６枚となる。ここで予め所定枚数を６枚とすると、この図示例では６枚であるので、第２の計画作成手段１５ｂは、板取り品番Ａの扉材を２枚分板取りすることになっている７枚目の原板１００の残り部位（余り部位）には２枚の品番Ａの扉材の板取り割り付けて他の６枚の原板１００と同一の板取りパターンとし、この板取りを行った２枚の扉材をフリー在庫とする。
【００８４】
さて各原板１００では４枚の板取りを行っても端部に残り部位（余り部位）ｃが発生することになるが、この残り部位ｃの長さが、図９（ｂ）に示すように扉材を板取りできる下限長さに対応する所定の基準値以上であれば、この残り部位ｃに対して板取り可能な品番Ｙの扉材の板取りを割り付け、当該品番Ｙの扉材もフリー在庫とする。
【００８５】
つまり図９の場合には一枚の原板１００から４枚の品番Ａの扉材と１枚の品番Ｙの扉材の板取りを割り付けることができることになる。
【００８６】
ところで、品番Ａの扉材必要数が１８の場合には図１０に示すように上記の原板１００を５枚用い、その内の４枚が同一板取りパターンとなる。この場合同一板取りパターンの原板１００の枚数が所定枚数６より少ないため、第２の計画作成手段１５ｂは、２枚分の品番Ａの扉材の板取りを行う原板１００の残り部位に対して需要優先度情報に基づいて決定された選定順位に沿って板取りを割り付ける。この場合まず優先度の高い品番、例えば品番Ｃの扉材を割り付け、更に品番Ｄの扉材を割り付け、これら品番Ｃ，Ｄの扉材をフリー在庫とする。更に各原板１００の端部の残り部位ｃで板取り可能な上述の品番Ｙの扉材の板取りを行ってこの扉材もフリー在庫としても良い。
【００８７】
かように本例では同一板取りパターンの原板１００が所定枚数（例では６枚）以上となる場合には、同一板取りパターンとならない原板１００の残り部位に対して板取りの割り付け済みの品番と同一の品番の扉材の板取りを割り付けことにより、歩留まりと、生産性を高めることが可能な第２の板取計画を立案作成する。
【００８８】
（例ｉｉ）
本例の第２の計画作成手段１５ｂは、生産を必要とする全ての品番の扉材に対する必要な枚数の板取りが終了した後、原板１００の残り部位（余り部位８）にフリー在庫用として需要優先度に基づいた品番の扉材の板取りを割り付けるに当たり、当該原板１００に対して先に板取りを割り付けた生産を必要とする品番の需要優先度が所定値（例えば１００以上）があれば当該品番の扉材の板取りを割り付け、この扉材をフリー在庫とし、所定値未満の場合には需要優先度順で選定した品番の扉材の板取りを割り付ける板取計画を立案する。
【００８９】
図１１（ａ）は需要優先度が例えば１５０の品番Ａの扉材を板取りした原板１００の残り部位（余り部位）に対してフリー在庫の扉材を板取りする場合を示しており、この場合品番Ａの扉材の需要優先度が所定値（例えば１００）以上であるので、残り部位に品番Ａの扉材の板取りを可能な限り割り付ける（ロット化する）。そしてこの板取り後に更に残った部位に対しては需要優先度順で品番を選定し、その品番、例えば品番Ｚの扉材の板取り割り付けを行う。
【００９０】
また図１１（ｂ）は需要優先度が例えば１０の品番Ｂの扉材を板取りした原板１００の残り部位（余り部位）に対してフリー在庫の扉材を板取りする場合を示しており、この場合品番Ｂの扉材の需要優先度が所定値（１００）未満であるので、残り部位には需要優先度順で品番を選定し、その品番、例えば優先順位の高い品番Ｚの扉材の板取り割り付けを行い、更に残った部位には、その部位の長さより扉材の長さが短い品番中優先順位が高い品番、例えばＶの扉材の板取りを行う。
【００９１】
更に図１１（ｃ）は需要優先度が例えば１２０の品番Ｃの扉材を板取りした原板１００の残り部位（余り部位）に対してフリー在庫の扉材を板取りする場合を示しており、この場合品番Ｃの扉材の需要優先度が所定値（１００）以上であるので、残り部位に品番Ｃの扉材の板取りを可能な限り（図示例では３枚分）割り付ける（ロット化する）。そしてこの板取り後に更に残った部位に対しては需要優先度順で品番を選定し、その品番の扉材の板取り割り付けを行う。図示例では更に残った部位の長さが所定以上でないため板取り割り付けを行っていない。
【００９２】
また図１１（ｄ）は需要優先度が例えば７０の品番Ｄの扉材を板取りした原板１００の残り部位（余り部位）に対してフリー在庫の扉材を板取りする場合を示しており、この場合品番Ｄの扉材の需要優先度が所定値（１００）未満であるので、残り部位には需要優先度順で品番、例えば品番Ｚを選定し、その品番Ｚの扉材の板取りの割り付けを行い、更に残った部位には、その部位の長さより扉材の長さが短い品番中優先順位が高い品番、例えばＶの扉材の板取りを行う。
【００９３】
このようにして本例では、需要優先度が高い品番については、同一品番の連続的な板取り、つまりロット生産化を図る板取りにより歩留まりと生産性を向上させることができる板取計画を立案作成する。
【００９４】
（例ｉｉｉ）
本例は、生産が必要な品番毎に対して原板を引き当てて板取りを行う板取計画を想定するとともに、夫々の原板での残り部位の長さが所定の長さ以上となる板取計画に対して、残り部位の長さが最小となるように夫々の板取計画を組み合わせて統合し、この統合した結果を最小となる板取計画として最終的に作成するのである。
【００９５】
図１２は必要数が例えば１３枚の品番Ａの扉材と、必要数が例えば３枚の品番Ｂの板材と、必要数が例えば３枚の品番Ｃの板材と、必要数が例えば３枚の品番Ｄの扉材とに対する板取計画を立案する際の流れを示しており、この例の場合には第２の計画作成手段１５ｂは、まず品番Ａに対して４枚の原板１００を引き当てて、１３枚の品番Ａの扉材の板取計画を図１２（ａ）に示すように作成する。同様に品番Ｂ〜Ｄに対して夫々１枚の原板１００を引き当てて、各原板１００に対して３枚の品番Ｂ〜Ｄの扉材の板取計画を図１２（ｂ）〜（ｄ）に示すように作成する。そして各原板１００において端部（図では右端）からの残り部位の長さが所定の基準値Ｌ以上となる板取計画から残り部位の長さが最小となるように図１２（ａ）〜（ｄ）の各品番Ａ〜Ｄの板取計画を統合する処理を行う。この場合図１２（ａ）〜（ｄ）の各板取計画を組み合わせてみて、原板１００の残り部位の長さが最も小さくなる組み合わせを抽出する。この場合組み合わせは同じ品番の扉材が連続的に生産、つまりロット生産できるように組み合わせる。
【００９６】
而して図１２の場合には品番Ａの扉材を１枚だけ板取りを行う原板１００の残り部位に品番Ｂ乃至Ｄの扉材の内扉材の長さが最も長い品番Ｂの扉材の板取計画である図１２（ｂ）の板取計画を組み合わせることで、原板１００の残り部位の長さを最小とすることができる。また図１２（ｃ）の品番Ｃの扉材の板取計画に対して同図（ｄ）の品番Ｄの扉材の板取計画を組み合わせることで、原板１００の残り部位の長さを同図（ｃ）や同図（ｄ）の場合の板取計画に比べて短くなる板取計画を図１２（ｅ）や（ｆ）に示すように作成することができる。而して立案計画手段１５ｂは、上述のように板取計画を統合した板取計画を最終的な板取計画として立案作成するのである。これにより板取に用いる原板１００の総数を減らすことができ、ロット生産化とともに生産性を向上させた板取計画を立案作成することができる。
【００９７】
（例ｉｖ）
上記例ｉｉｉでは板取計画を統合する形で、原板１００の残り部位の長さを最小とする板取計画を立案作成しているが、本例では、例えば上述と同様に必要数が１３枚の品番Ａの扉材と、必要数が３枚の品番Ｂの板材と、必要数が３枚の品番Ｃの板材と、必要数が３枚の品番Ｄの扉材とに対する板取計画を立案する際、まず第２の計画作成手段１５ｂは、上述と同様に品番Ａに対して４枚の原板１００を引き当てて、１３枚の品番Ａの扉材の板取計画を図１３（ａ）に示すように作成する。同様に品番Ｂ〜Ｄに対して夫々１枚の原板１００を引き当てて、各原板１００に対して３枚の品番Ｂ〜Ｄの扉材の板取計画を図１３（ｂ）〜（ｄ）に示すように作成する。そして各原板１００において残り部位の長さが所定以上となる板取計画から残り部位の長さが最小となるように図１３（ａ）〜（ｄ）の各品番Ａ〜Ｄの板取計画を統合する処理を行う。この場合図１３（ａ）〜（ｄ）の各板取計画を組み合わせてみて、原板１００の残り部位の長さが最も小さくなる組み合わせを抽出する。この場合組み合わせは同じ品番の扉材が連続的に生産、つまりロット生産できるように組み合わせる。ここまでは例ｉｉｉと同じであるが、本例では図１３（ｅ）（１３ｆ）のように統合されて得られた板取計画において、更に発生する原板１００の残り部位の長さが所定の基準値Ｌより長い場合には、フリー在庫数［＝（現庫数−注文引当在庫数−下限在庫数）］の在庫日数［＝フリー在庫数／月平均需要量）を基に算出したフリー在庫としての選定順序に基づいて在庫人数の少ないものから順に、可能なフリー在庫の板取りを更に行う。図１３（ｅ）の場合には生産が必要とされている品番Ａ又は品番Ｂの扉材を１枚板取りでき、また今回の板取計画では生産が必要でない品番Ｅの扉材を２枚板取りできる。同様に図１３（ｆ）の場合には生産が必要とされる品番Ｄの扉材の１枚又は上記の品番Ｅの扉材の１枚を板取りできる。
【００９８】
以上の例ｉ乃至例ｉｖの何れかの方法で第２の板取計画結果を第２の計画作成手段１５ｂで作成し、第２の板取結果格納データベースＤ１５ｂに格納する。
【００９９】
そして本発明生産計画作成システムではデータベースｄ１５，Ｄ１５ｂに夫々格納された第１，第２の板取計画結果の何れかを板取計画評価手段１６により最終的な板取計画として決定するのであるが、この決定は図１４に示すフローチャートに基づいて行われる。
【０１００】
つまり板取計画評価手段１６は板取評価基準情報データベースＤ１６に格納されている歩留まり、生産性（加工時間、品種数）のデータと、在庫情報データベースＤ１４から在庫日数データを取り込み、第１の板取計画結果と第２の板取計画結果とに対して色柄、扉幅（原板幅）別にそれらデータを集計する（Ｓ１）。
【０１０１】
具体的には評価項目データとして、原板使用枚数、原板使用長さ（同一原板幅に対し、長さが異なるものがあるため）、扉材生産枚数（フリー在庫扉の生産枚数も含む）、扉材フリー在庫生産枚数（フリー在庫数／扉標準品番単位での月平均需要量）、扉材生産長さ（各部材の製品サイズ）、生産時間（各板取計画毎に、加工プログラム設定時間と加工時間、段取り作業時間を集計＜プログラム設定時間は板取計画のパターンの変更毎に時間加算（同一パターンであれば零とする。また加工時間は切断回数×平均時間で計算する。また段取り作業時間は、必要原板数×平均搬入時間、生産扉材数×平均搬出時間で計算＞）、加工プログラム設定回数（予め設定された標準加工パターン＜単一品番カット，使用頻度が多い加工パターン＞以外の加工プログラムへの設定回数）、加工品種数（一原板から切断する扉材の品種数＜サイズ単位＞を集計）を集計する。
【０１０２】
次のステップＳ２では、色柄と扉幅毎に集計した歩留まり、加工時間、品種数、在庫日数に対して予め板取評価基準情報データベースＤ１６に格納してある所定の重み係数を乗じて評価値を算出する。そして次のステップＳ３で色柄と扉幅毎に上記評価値を比較し、色柄と扉幅毎に採用する板取計画を決定する。
【０１０３】
ここで、原板の色柄，原板幅毎の評価値として具体的は次のものがある。
【０１０４】
歩留まり ＝扉材生産長さ／原板使用長さ
フリー在庫生産比率＝扉材フリー在庫生産枚数／扉材生産枚数
フリー在庫日数 ＝扉材フリー在庫数／月平均需要量
（在庫日数評価は，当日生産分のみではなく、現段階でのフリー在庫量から算出）
時間生産性 ＝扉材生産枚数／生産時間
プログラム回数 ＝加工プログラム設定回教／原板使用枚数
切断品種数 ＝加工品種数／原板使用枚数
そして総合評価を行うための総合評価値と、現状の重み付け係数は次のものが採用する。
【０１０５】
総合評価値 ＝歩留まり×α＋（フリー在庫比率月次基準／フリー在庫生産比率）×β＋（時間生産性／生産時間性月次基準）×γ
尚フリー在庫生産比率月次基準は、フリー在庫生産比率の月平均情報を基に、予め基準値を設定する。 時間生産性月次基準は、時間生産性の月平均情報を基に、予め基準値を設定する。また上記評価値の式では、歩留まり、フリー在庫、時間生産性の夫々の評価データの基準値を１．０に換算し、係数（α、β、γ）で補正する。
【０１０６】
重み付け係数（現在設定値）
α＝６．０
β＝３．０
γ＝１．０
板取計画としては、原板の色柄，原板幅毎に上記総合評価値が高い板取計画を採用する。そして重み付け係数の設定については、生産の状況、在庫の状況に応じて以下のように調整する。
【０１０７】
歩留まりが低い場合にはα値を高くする。またフリー在庫が多い場合にはβ値を高くする。そして必要に応じて、α値を低くする。生産性が低い場合にはγ値を高くする。そして必要に応じて、α値を低くする。
【０１０８】
以上のような総合評価値や重み付けにより採用が決定された板取計画は記憶装置３に格納される（Ｓ４）。この後実際の生産前に、記憶装置３に格納されている板取計画より所定形式の生産指示書を作成し、プリンタ等の出力装置４より出力する。
【０１０９】
このように板取評価基準情報となる歩留まり、生産性、重み付け係数などをデータベースＤ１６に格納することにより、評価基準の変更を可能とし、また板取評価値に従って、色柄と扉幅毎に板取り評価結果が良い方の板取計画を採用することにより、需要と生産性の両方を考慮した高い歩留まりを実現する板取計画を作成して提供することができる。また採用された板取計画を記憶装置３に格納することにより、必要なタイミングでの採用された板取計画を取り指すことができる。
【０１１０】
尚本発明は、箱形商品の扉材以外に、板取りを行う必要のある部材一般に適用できるのは勿論である。
【０１１１】
【発明の効果】
請求項１の生産計画作成方法の発明は、板取り対象の製品の扉材の幅と同一幅で定尺の原板から、扉材の高さ方向が原板の長手方向となるように扉材を切り取る際に用いる板取計画を作成する生産計画作成方法において、需要頻度に関するマスタ情報や生産対象となる各製品に関するマスタ情報、製品の在庫情報を夫々格納したデータベース部から読み出したマスタ情報に基づいて製品の需要優先度を算出する過程と、今回の受注製品の注文情報と上記データベース部に格納されている当該製品の在庫情報とから必要な生産数を算出する過程と、今回の受注によって生産が必要となった製品の扉材を対象に、扉材の板取り優先順に原板の引き当てと扉材の板取りとを繰り返して行い、板取り状態の原板の残り部位の長さが、生産を必要とする全ての扉材に対して板取りが不可能な寸法となった際に、上記需要優先算出手段で算出した需要優先度の順に従って板取り可能な製品の扉材を選定して上記原板の残り部位から板取りを行う第１の板取計画を自動作成する第１の計画作成過程と、今回の受注によって生産が必要となった製品の扉材を対象に、製品の１品番毎に原板の引き当てと扉材の板取りとを繰り返して行い、生産が必要となった全ての製品の扉材に対する板取りを行った後、残り部位の長さが所定の寸法より大きい板取り状態の原板に対して、上記各品番毎の板取りにより作成される板取計画を統合により、若しくは上記需要優先算出手段で算出した需要優先度の順に従って、板取り可能な製品の扉材を選定することにより、上記原板の残り部位から板取りを行う第２の板取計画を自動作成する第２の計画作成過程と、第１，第２の計画作成過程が夫々作成する板取計画に対して、扉材の色柄及び扉材の幅毎に少なくとも歩留まり、生産性、在庫日数について評価を行い、最終的に採用する計画作成を決定する板取計画評価過程とから成るので、品番毎の需要傾向を考慮したフリー在庫の生産を加味した、歩留まりと生産性の高い板取計画を短時間に作成することができるという効果がある。
【０１１２】
請求項２の生産計画作成システムの発明は、需要頻度に関するマスタ情報や生産対象となる各製品に関するマスタ情報、製品の在庫情報を夫々格納したデータベース部と、該データベース部から読み出したマスタ情報に基づいて製品の需要優先度を算出する需要優先度算出手段と、今回の受注製品の注文情報と上記データベース部に格納されている当該製品の在庫情報とから必要な生産数を算出する生産必要数算出手段と、今回の受注によって生産が必要となった製品の扉材を対象に、扉材の板取り優先順に原板の引き当てと扉材の板取りとを繰り返して行い、板取り状態の原板の残り部位の長さが、生産を必要とする全ての扉材に対して板取りが不可能な寸法となった際に、上記需要優先算出手段で算出した需要優先度の順に従って板取り可能な製品の扉材を選定して上記原板の残り部位から板取りを行う第１の板取計画を自動作成する第１の計画作成手段と、今回の受注によって生産が必要となった製品の扉材を対象に、製品の１品番毎に原板の引き当てと扉材の板取りとを繰り返して行い、生産が必要となった全ての製品の扉材に対する板取りを行った後、残り部位の長さが所定の寸法より大きい板取り状態の原板に対して、上記各品番毎の板取りにより作成される板取計画を統合により、若しくは上記需要優先算出手段で算出した需要優先度の順に従って、板取り可能な製品の扉材を選定することにより、上記原板の残り部位から板取りを行う第２の板取計画を自動作成する第２の計画作成手段と、第１，第２の計画作成手段が夫々作成する板取計画に対して、扉材の色柄及び扉材の幅毎に少なくとも歩留まり、生産性、在庫日数について評価を行い、最終的に採用する計画作成を自動決定する板取計画評価手段とを備えているので、品番毎の需要傾向を考慮した負Ｒ−在庫の生産を加味した、歩留まりと生産性の高い板取計画を短時間に且つ自動的に作成することができるという効果がある。
【０１１３】
請求項３の生産計画作成システムの発明は、請求項２の発明において、上記需要優先度算出手段が、板取りされる各製品の品番を扉材の色柄、原板幅、扉材の高さ方向のによりグループ化した標準品番の単位で、前月の需要量と過去の所定月数の平均需要量に対し、前月の需要傾向を重視する所定の重み付けを行って補正した月平均需要量を算出し、該月平均需要量の多い製品の扉材から需要優先度を決定する算出手段であるので、常に製品の需要量に連動した優先度に基づいた板取計画が行え、特に重み付けによって直近の需要傾向を大きく反映させた優先度の管理ができるため、高い精度で管理した優先度に基づいた板取計画を作成することが可能になるという効果がある。
【０１１４】
請求項４の生産計画作成システムの発明は、請求項２の発明において、上記需要優先度算出手段が、板取りされる各製品の品番を扉材の色柄、原板幅、扉材の高さ方向のによりグループ化した標準品番毎に、販売月数が予め想定した所定月数に満たない製品について、前月の需要傾向を重視する所定の重み付けを行って補正した月平均需要量を算出し、該月平均需要量の多い製品の扉材から需要優先度を決定する算出手段であるので、販売月数が不足して所定月数の平均需要量が算出できない製品に対しては前月の需要傾向を基に算出される月平均需要に基づいた需要優先度を基にした板取計画を作成することが可能になるという効果がある。
【０１１５】
請求項５の生産計画作成システムの発明は、請求項２又は３の発明において、上記生産必要数算出手段が、所定期間に受注された製品の品番毎の注文数と現在の在庫数と下限在庫数とを基に生産に必要な扉材の数を算出する算出手段であるので、納期変更による出荷延期納品や、クレーム、督促などによる在庫品の予定外の出庫による在庫状況の変動にも対応した生産必要数に基づいた板取計画を作成することが可能になるという効果がある。
【０１１６】
請求項６の生産計画作成システムの発明は、請求項２乃至５の何れかの発明において、上記第１の計画作成手段が、生産が必要な製品の扉材を対象に原板から板取りを行う際に、高さ方向の長さが長い順に扉材の板取り優先順を決めて第１の板取計画を作成するので、短時間での板取計画の作成が可能となり、しかも原板の残り部位の長さ寸法を小さくすることが可能となるため、フリー在庫用の扉材の生産を最小限にした上で歩留まりを高めた板取計画を作成することが可能になるという効果がある。
【０１１７】
請求項７の生産計画作成システムの発明は、請求項２乃至５の何れかの発明において、上記第１の計画作成手段が、生産が必要な製品の扉材を対象に原板から板取りを行う際に、必要数の多い扉材から順に板取り優先順を決めて第１の板取計画を作成するので、同一品番の製品の扉材のロット生産（まとめ切断）が可能で生産性を高めることができる板取計画を作成することが可能になるという効果がある。
【０１１８】
請求項８の生産計画作成システムの発明は、請求項６又は７の発明において、上記第１の計画作成手段が、上記板取り優先順に、原板の引き当て、扉材の板取りを繰り返して行い、板取り状態の原板の残り部位の長さが、生産に必要な全ての製品の扉材の板取りができない寸法となったとき、現在庫数から注文引き当て在庫数と下限在庫数とを減算して求まるフリー在庫数に対する在庫日数を基にフリー在庫としての選定順序を決定し、上記原板の残り部位から上記選定順序に基づいてフリー在庫用の扉材の板取りを行う第１の板取計画を作成するので、フリー在庫として生産する扉材を需要量に併せることができる板取計画を作成することが可能となるという効果がある。
【０１１９】
請求項９の生産計画作成システムの発明は、請求項８の発明において、上記フリー在庫日数が所定の基準日数を超えた場合に、上記原板の残り部位からの板取りを止めるので、フリー在庫となる扉材の生産過剰を抑制した板取計画を作成することが可能になるという効果がある。
【０１２０】
請求項１０の生産計画作成システムの発明は、請求項８の発明において、上記フリー在庫の数が所定の基準数を超えた場合に、上記原板の残り部位からの板取りを止めるので、月平均の需要量が非常に大きくてフリー在庫日数が小さくなる品番の製品に対応した扉材のフリー在庫の絶対量が大きくなる現象を防ぐことが可能となり、その結果在庫スペースを一定量以内に保つことができる板取計画を作成することが可能になるという効果がある。
【０１２１】
請求項１１の生産計画作成システムの発明は、請求項６又は８の発明において、上記第１の計画作成手段が、上記板取り優先順に、原板の引き当て、扉材の板取りを繰り返して行い、板取り状態の原板の残り部位の長さが、生産に必要な全ての製品の扉材の板取りができない寸法となったとき、予め特定してあるフリー在庫対象の品番の製品の扉材を上記原板の残り部位から板取りを行う第１の板取計画を作成するので、フリー在庫として板取りされにくい高さ方向の長さが長い扉材に対応する特定の品番のフリー在庫を意図的に生産する板取計画を作成することが可能になるという効果がある。
【０１２２】
請求項１２の生産計画作成システムの発明は、請求項２乃至１１の何れかの発明において、上記第２の計画作成手段が、生産が必要な製品の扉材を対象に定尺の原板から板取りを行う際に、製品の品番単位で原板からの扉材の板取りを繰り返して行って生産が必要な全て製品の品番に対する板取りを行った後、同じ板取りパターンの原板が予め決めてある所定枚数以上ある場合に、これら原板の板取り対象の品番と同一品番の製品の扉材の板取りを行い且つ異なる板取りパターンとなった原板の残り部位に対して当該原板に割り付け済みの品番と同一品番の製品の扉材をフリー在庫用として板取りを行う第２の板取計画を作成するので、歩留まりと生産性を高めることができる板取計画の作成が可能となるという効果がある。
【０１２３】
請求項１３の生産計画作成システムの発明は、請求項２乃至１１の何れかの発明において、上記第２の計画作成手段が、生産が必要な製品の扉材を対象に定尺の原板から板取りを行う際に、製品の品番単位で原板からの扉材の板取りを繰り返して行って生産が必要な全て製品の品番に対する板取りを行った後、原板に割り付けた品番の需要優先度が予め定めた所定値以上の場合に、当該原板の残り部位に割り付け済みの品番と同一品番の製品の扉材をフリー在庫用として板取りを行う第２の板取計画を作成するので、同じ品番の製品の扉材を連続的に生産して、歩留まりと生産性を向上させることができる板取計画を作成することが可能になるという効果がある。
【０１２４】
請求項１４の生産計画作成システムの発明は、請求項２乃至１１の何れかの発明において、上記第２の計画作成手段が、生産が必要な製品の扉材を対象に定尺の原板から板取りを行う際に、製品の品番単位で原板からの扉材の板取りを繰り返して行って生産が必要な全て製品の品番に対する板取りを行った後、原板の残り部位の長さが所定寸法以上の板取計画を、原板の残り部位の長さが最小となる板取計画となるように統合して第２の板取計画を作成するので、フリー在庫となる扉材の生産を抑え、同一品番の連続生産により、生産性を向上させることができる板取計画を作成することが可能になるという効果がある。
【０１２５】
請求項１５の生産計画作成システムの発明は、請求項２乃至１１及び１４の何れかの発明において、上記第２の計画作成手段が、生産が必要な製品の扉材を対象に定尺の原板から板取りを行う際に、製品の品番単位で原板からの扉材の板取りを繰り返して行って生産が必要な全て製品の品番に対する板取りを行った後、残り部位の長さが所定寸法以上の原板に対して、現在庫数から注文引き当て在庫数と下限在庫数とを減算して求まるフリー在庫数に対する在庫日数を基にフリー在庫としての選定順序を決定し、上記原板の残り部位から上記選定順序に基づいてフリー在庫用の扉材の板取りを行う第２の板取計画を作成するので、フリー在庫となる扉材の生産を抑え、同一品番の連続生産により、歩留まりと生産性を向上させることができる板取計画を作成することが可能になるという効果がある。
【０１２６】
請求項１６の生産計画作成システムの発明は、請求項２乃至１５の何れかの発明において、板取計画の評価基準用として、扉材の色柄、扉幅別に歩留まり、生産性、在庫日数の各情報を格納したデータベース部を備え、上記板取計画評価手段は、第１，第２の板取計画に対して扉材の色柄、扉幅別に、歩留まり、生産性、在庫日数を集計して、これら集計した歩留まり、生産性、在庫日数に対する評価値を算出し、第１，第２の板取計画の扉材の色柄、板幅毎に評価値を比較して最終的に採用する板取計画を決定するので、扉材の色柄と扉幅毎に需要と生産性の両方を考慮した評価により板取計画を決定できるため、高い歩留まりを実現する板取計画を作成できるという効果がある。
【０１２７】
請求項１７の生産計画作成システムの発明は、請求項１６の発明において、上記評価値の算出時に所定の重み付けを行って補正するので、在庫や生産状況に対応した評価値が得られる。
【０１２８】
請求項１８の生産計画作成システムの発明は、請求項２乃至１７の何れかの発明において、上記板取計画評価手段で最終的に決定された板取計画のデータを格納する記憶媒体を備えているので、必要なタイミングで最終的に決定された板取計画を取り出すことが可能となる。
【図面の簡単な説明】
【図１】本発明の全体システム構成図である。
【図２】同上の第１の計画作成手段の動作説明用フローチャートである。
【図３】同上の第１の計画作成手段における扉品番板取計画割付処理の例１の説明図である。
【図４】同上の第１の計画作成手段における扉品番板取計画割付処理の例２の説明図である。
【図５】同上の第１の計画作成手段におけるフリー在庫の選定順位の決定方法の例Ｉの説明用フローチャートである。
【図６】同上の第１の計画作成手段におけるフリー在庫の選定順位の決定方法の例ＩＩの説明用フローチャートである。
【図７】同上の第１の計画作成手段におけるフリー在庫の選定順位の決定方法の例ＩＩＩの説明用フローチャートである。
【図８】同上の第１の計画作成手段におけるフリー在庫の選定順位の決定方法の例ＩＶの説明用フローチャートである。
【図９】同上の第２の計画作成手段で採用する板取計画方法の例ｉの一方法の説明図である。
【図１０】同上の第２の計画作成手段で採用する板取計画方法の例ｉの他方法の説明図である。
【図１１】同上の第２の計画作成手段で採用する板取計画方法の例ｉｉの一方法の説明図である。
【図１２】同上の第２の計画作成手段で採用する板取計画方法の例ｉｉｉの一方法の説明図である。
【図１３】同上の第２の計画作成手段で採用する板取計画方法の例ｉｖの一方法の説明図である。
【図１４】同上の板取計画評価手段の動作説明用フローチャートである。
【符号の説明】
１ 生産計画作成システム
２ 生産管理システム
３ 記憶装置
４ 出力装置
５ 入力装置
１０ コンピュータ部
１１ 需要優先度算出手段
１２ 生産必要数算出手段
１３ 板取パラメータ設定手段
１４ 板取計画自動作成部
１５ａ 第１の計画作成手段
１５ｂ 第２の計画作成手段
１６ 板取計画評価手段
Ｄ１１ 需要頻度マスタデータベース
Ｄ１２ 品番マスタデータベース
Ｄ１３ 注文情報データベース
Ｄ１４ 在庫情報データベース
Ｄ１５ａ 第１の板取計画結果格納データベース
Ｄ１５ｂ 第２の板取計画結果格納データベース
Ｄ１６ 板取評価基準情報データベース
Ｄ２１ 在庫情報データベース
Ｄ２２ 注文情報データベース
Ｄ２３ 入出庫履歴情報データベース[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a production plan creating method and a system therefor in sheet picking.
[0002]
[Prior art]
Conventionally, as a method of creating a production plan when removing parts of a product from an original plate, a method of preparing a plate that takes into account both the productivity (yield, operation rate) and the delivery date in the plate removal for ordered products is considered. A method of creating a production plan to be performed is provided (Patent Document 1).
[0003]
Further, as a method of creating a production plan for cutting and processing a fixed-length member, a method has been conventionally provided in which a high yield is achieved by removing a piece of scrap from a stock member that is frequently required. Reference 2).
[0004]
In addition, there is also a method in which a free stock is allocated to a surplus portion (Patent Document 3), and a method in which members are cut in order of demand priority (Patent Document 4).
[0005]
[Patent Document 1]
JP-A-2000-351527
[Patent Document 2]
JP-A-2-242303
[Patent Document 3]
JP-A-5-138432
[Patent Document 4]
JP-A-2002-351527
[0006]
[Problems to be solved by the invention]
By the way, in the former conventional example of the conventional method of the above-mentioned Patent Document 1, although both the productivity (yield, operation rate) and the delivery time of the board removal are considered, the demand tendency is considered, that is, the selection of the free stock. And it does not carry out stripping.
[0007]
Further, in this conventional example, the existing layout information is once decomposed and redeployed in order to improve the yield by reconstructing the layout of the layout size. Therefore, the yield was not improved.
[0008]
Further, in the conventional example of Patent Document 2, the yield is increased by removing the scraps with a frequently used stock member, but the upper limit of the number of stock members is limited to a large variety of small products. Due to the problem of reaching, high yield could not be realized.
[0009]
Furthermore, in this conventional example, since the production method is a board stocking and free inventory based on a production order constraint, the yield cannot be improved for the product number of the ordered product and the production item itself on the day.
[0010]
The present invention has been made in view of the above points, and an object of the present invention is to improve the yield and productivity when removing a door material corresponding to an ordered product from an original plate. The present invention provides a production plan creation method and a system therefor.
[0011]
[Means for Solving the Problems]
In order to achieve the above object, in the invention of the production plan creation method according to claim 1, the height direction of the door material is set to be the same as the width of the door material of the product to be trimmed, In a production plan creation method that creates a board plan to be used when cutting the door material so that it becomes the direction, from the database unit that stores master information about demand frequency, master information about each product to be produced, and product inventory information Calculating the demand priority of the product based on the read master information; and calculating the required production quantity from the order information of the current ordered product and the stock information of the product stored in the database unit. For the door materials of the products that need to be produced by this order, we will repeat the assignment of the original plate and the removal of the door material in the order of the priority of the door material removal, and the rest of the original material in the plate removal state When the length of the product becomes a dimension that makes it impossible to cut out all door materials that require production, the products that can be cut out according to the order of the demand priority calculated by the demand priority calculation means above A first plan creation process for automatically creating a first boarding plan in which door materials are selected and boarding is performed from the rest of the original sheet, and door materials for products that need to be produced due to this order After repeating the assignment of the original plate and the removal of the door material for each part number of the product, and the removal of the door materials of all the products that need to be produced, the length of the remaining portion is a predetermined length. Products that can be boarded according to the order of demand priorities calculated by the demand priority calculation means by integrating the boarding plans created by boarding for each part number for original sheets in boarding state larger than dimensions By selecting the door material of For the second plan creation process for automatically creating the second plan creation plan for performing the board removal from the part and the plan design created by the first and second plan creation processes, respectively, the color and pattern of the door material and the door material It is characterized in that it comprises at least the yield, productivity, and the number of days of stock for each width, and a planing plan evaluation process for finally deciding the plan to be adopted.
[0012]
According to the invention of the production plan creation system of claim 2, the door material is formed from a fixed-size original plate having the same width as the width of the door material of the product to be trimmed so that the height direction of the door material becomes the longitudinal direction of the original plate. In a production plan creation system for automatically creating a board plan to be used for cutting, a master section on demand frequency, master information on each product to be produced, and a database section storing product inventory information, respectively, were read from the database section. A demand priority calculating means for calculating a demand priority of the product based on the master information; and a required production quantity is calculated from the order information of the current ordered product and the stock information of the product stored in the database unit. Repeat the allocation of the original plate and the door material in the order of the priority of the door material removal for the door material of the products that need to be produced due to this order When the length of the remaining portion of the original plate in the stripping state becomes a dimension that cannot be stripped for all door materials that require production, the demand calculated by the demand priority calculation means A first plan creation means for automatically creating a first boarding plan for selecting a door material of a board that can be boarded according to the order of priority and performing boarding from the remaining portion of the original sheet; For the door materials of the products that are needed, we will repeat the assignment of the original plate and the removal of the door materials for each product number, and the removal of the door materials of all the products that require production. After that, the length of the remaining part is larger than the predetermined size. For the original plate in the boarding state, the boarding plan created by the boarding for each part number is integrated, or the demand calculated by the demand priority calculation means is calculated. Door materials for products that can be boarded according to the order of priority By selecting, the second plan making means for automatically preparing a second plan drawing plan for performing planing from the remaining portion of the original sheet, and the plan drawing plan prepared by the first and second plan producing means respectively. , At least a yield for each color and pattern of the door material and the width of the door material, a productivity, an evaluation on the number of days in stock, and a planing plan evaluation means for automatically determining the final preparation of the plan. I do.
[0013]
According to a third aspect of the present invention, in the second aspect of the present invention, the demand priority calculating means determines a product number of each product to be boarded by a color and a pattern of a door material, an original plate width, and a height of a door material. Calculates the monthly average demand in the unit of standard part number grouped by direction, corrected by applying a predetermined weighting to the demand in the previous month and the average demand in the past predetermined number of months to emphasize the demand trend in the previous month And it is a calculating means for determining a demand priority from a door material of a product having a large monthly average demand.
[0014]
According to a fourth aspect of the present invention, in the second aspect of the invention, the demand priority calculating means calculates a product number of each product to be cut out by using a color and pattern of a door material, an original plate width, and a height of a door material. For each standard part number grouped by direction, for products whose sales months are less than the predetermined number of months assumed in advance, calculate the monthly average demand amount corrected by performing a predetermined weighting that emphasizes the demand trend of the previous month, It is a calculating means for determining a demand priority from a door material of a product having a large monthly average demand.
[0015]
In the production plan creation system according to claim 5, in the invention according to claim 2 or 3, the required production quantity calculating means includes: an order quantity, a current stock quantity, and a lower limit stock quantity for each product number ordered in a predetermined period. It is a calculating means for calculating the number of door materials necessary for production based on the number.
[0016]
According to a sixth aspect of the present invention, in the invention of any one of the second to fifth aspects, the first plan creator performs board trimming from an original sheet for door materials of products requiring production. In this case, a first boarding plan is created by deciding the boarding priority of door materials in descending order of length in the height direction.
[0017]
According to a seventh aspect of the present invention, in the production plan creating system according to any one of the second to fifth aspects, the first plan creating means performs board trimming from an original sheet for door materials of products requiring production. In this case, the first boarding plan is created by deciding the boarding priority order in the order of the door materials having a large number of required numbers.
[0018]
In the invention of the production plan creation system of claim 8, in the invention of claim 6 or 7, the first plan creation means repeatedly performs the assignment of the original plate and the plate removal of the door material in the plate removal priority order, When the length of the remaining part of the original sheet in the board-cutting state is such that the door material of all the products necessary for production cannot be cut out, subtract the order reserved inventory quantity and the lower limit inventory quantity from the current inventory quantity. A first stocking plan in which the order of selection as free stock is determined based on the number of days of stock with respect to the number of free stocks determined in accordance with the above, and door materials for free stock are trimmed from the remaining portion of the original sheet based on the above selection order. It is characterized in that it is created.
[0019]
According to a ninth aspect of the present invention, in the invention of the eighth aspect, when the number of free stock days exceeds a predetermined reference number of days, the board removal from the remaining portion of the original sheet is stopped. .
[0020]
According to a tenth aspect of the invention, in the production plan creating system according to the eighth aspect, when the number of the free stocks exceeds a predetermined reference number, the plate removing from the remaining portion of the original plate is stopped. I do.
[0021]
In the invention of the production plan creating system according to claim 11, in the invention according to claim 6 or 8, the first plan creating means repeatedly performs the assignment of the original plate and the plate removal of the door material in the plate removal priority order, If the length of the remaining part of the original sheet in the board removal state is such that the door material of all the products necessary for production cannot be removed, the door material of the product number of the free stock target specified in advance is The method is characterized in that a first planing plan for performing planing from the remaining portion of the original plate is created.
[0022]
In the production plan creation system according to the twelfth aspect, in the invention according to any one of the second to eleventh aspects, the second plan creation means is provided for converting door materials of products requiring production from a fixed-size original plate to a plate. When performing the picking, after repeatedly removing the door material from the original plate for each product part number and performing the board removal for all the product numbers that require production, the original sheet with the same boarding pattern is determined in advance If the number of sheets is equal to or greater than a predetermined number, the door material of the product having the same part number as the part number to be cut out of these base sheets is cut out, and the remaining parts of the base sheet having a different boarding pattern are assigned to the original sheet. It is characterized in that a second plan-cutting plan is prepared in which a door material of a product having the same part number as the part number is used as a free stock for planing.
[0023]
According to a thirteenth aspect of the invention of the production plan creating system, in any one of the second to eleventh aspects, the second plan creating means is configured to convert a fixed-size original plate to a door material of a product requiring production. When performing the picking, after repeatedly removing the door material from the original plate for each product part number and performing plate removal for all product numbers that require production, the demand priority of the part numbers assigned to the original plate In the case where the value is equal to or more than a predetermined value, a second planing plan is prepared in which a door material of a product having the same part number as the part number already allocated to the remaining portion of the original plate is planed for free stock. .
[0024]
In the invention of the production plan creating system according to claim 14, in the invention according to any one of claims 2 to 11, the second plan creating means is provided for converting door material of a product requiring production from a fixed-size original plate to a plate. When removing the door material, repeat the removal of the door material from the original plate for each product part number. It is characterized in that the above-mentioned plan is integrated so that the length of the remaining portion of the original plate becomes the minimum, and a second plan is created.
[0025]
In the invention of a production plan creating system according to claim 15, in the invention according to any one of claims 2 to 11 and 14, the second plan creating means is a fixed-size original plate for a door material of a product requiring production. When performing board removal from the original product, repeat the board removal of the door material from the original sheet for each product number, and after performing the board removal for all the product numbers that require production, the length of the remaining part is the specified dimension For the above original sheets, the order of selection as free inventory is determined based on the number of days of stock for the free inventory number obtained by subtracting the order reserved inventory number and the lower limit inventory number from the current inventory number. It is characterized in that a second planing plan for performing planing of door materials for free stock is created based on the selection order.
[0026]
In the invention of the production plan creating system of claim 16, in any one of the inventions of claims 2 to 15, each of the yield, productivity, and the number of days in stock for each of the color and pattern of the door material and the door width is used as an evaluation standard of the boarding plan. A database unit storing information is provided, and the planing plan evaluation means collects the yield, productivity, and number of days of stock for each of the first and second planing plans by color and pattern of the door material and door width. Calculate the evaluation values for the totaled yield, productivity, and number of days in stock, compare the evaluation values for each color and pattern of the door material and the width of the first and second planning plans, and determine the plan to finally adopt. It is characterized by doing.
[0027]
According to a seventeenth aspect of the invention, there is provided the production plan creating system according to the sixteenth aspect, wherein the evaluation value is corrected by performing predetermined weighting when calculating the evaluation value.
[0028]
In the invention of a production plan creating system according to claim 18, in any one of claims 2 to 17, there is provided a storage medium for storing data of the board plan finally determined by the board plan evaluation means. It is characterized by.
[0029]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described with reference to embodiments.
[0030]
FIG. 1 shows a system configuration diagram of the present invention, and a production plan creation system 1 of the present invention is a system for producing a box material for a house (for example, furniture, a storage crate, a system wash basin, and a system kitchen). This is a system for creating a production plan, which is linked to a production management system 2 for managing order (order) information, stock information, and stocking / delivery history information. On the production management system 2 side, the inventory quantity for each door part number set corresponding to each door material applied to the above box-shaped product, and the various standard length original sheets for setting the door material are set. The stock quantity for each original plate part number is stored in the inventory management database D21, the required number in the assembling process of the door part number corresponding to the ordered product is stored in the order information database D22. The history (number of issues in the previous month, number of issues in the current month, average number of issues in the past three months) is stored in the entry / exit history information database D23, and the host computer unit 20 of the production management system 2 sends a request from the production plan creation system 1. Accordingly, for example, at a predetermined time before the start of the production, the order information, the stock information, and the stocking / delivery history information are provided to the production plan creation system 1 online. In other words, the production management system 2 functions as a cycle history creation device, an order information creation device, and a stock information creation device. Of course, these devices may be added to the production plan creation system 1.
[0031]
The production plan creation system 1 is composed of a computer system, and receives from the entry / exit history information database D23 of the production management system 2 information on the number of issues per month for the last month, the number of issues per month, and the average number of issues per month in the past three months. The demand frequency master database D11 stored as the demand frequency master stored and information such as the color and pattern of the door material, the plate width (width in the left-right direction of the door), and the end material processing category for each door product number. An order that receives from the order information database D22 of the production management system 2 information on the number of orders for each door part number corresponding to the ordered product, and stores the information as order information. The information database D13 and the inventory information database D22 of the production management system 2 correspond to each door material applied to the box-shaped product. Receives information such as the current number of stocks and the lower limit stock number for each specified door part number, and the number of stocks for each original part number set in correspondence with various fixed-size original sheets for door materials. A stock information database D14 stored as stock information, a first planing plan result storage database D15a for storing planing plan production results, and a second planing plan result storage database D15b for storing planing plan production results as described later. Further, a database section D16 for evaluation of a planner evaluation standard information for storing a planner evaluation standard information for evaluating a planner plan described later is provided as a database section.
[0032]
The computer unit 10 realizes the function of the automatic planing plan creation unit 14 by executing a program. The storage unit 3 stores the finally selected planing plan information other than the database unit, and a door based on the planing plan. An output device 4 such as a printer or a monitor device for outputting an instruction form for material production instructions, and a set-up parameter setting means 13 for setting set-up parameters such as production information setting, setting of a set-up method, and equipment attributes used for the set-up. An input device 5 such as a keyboard for inputting information to be set by the user is provided.
[0033]
The planing plan automatic creation unit 14 includes first and second plan creation units 15a and 15b, and first and second plan creation units 15a and 15b created by the first and second plan creation units 15a and 15b. And a planing plan evaluation means 16 for finally determining the planing plan based on the planing evaluation reference information from the planing plan result of 2.
[0034]
Next, a flow until the production plan creation system 1 of the present invention creates the first planing plan will be described.
[0035]
First, the demand priority calculating means 11 of the computer unit 10 groups the standard product numbers (door product numbers in the direction of the door pattern, original plate width, and height of the door material) based on the product number master stored in the product number master database D12. Calculate the monthly average demand in the unit of the previous month and the average demand in the past predetermined number of months (N months) by adding a predetermined correction that emphasizes the demand trend in the previous month, and calculate the demand priority (Demand index) is determined.
[0036]
Here, in the example shown in Table 1, when the monthly average demand and the demand priority (demand index) are calculated, the result shown by the following formula is obtained.
[0037]
[Table 1]

[0038]
in this case,
Standard part A average monthly demand = [(7 + 33 + 0) x (1.0 + α) + (20 + 100 + 3) x (1.0 + β) + (14 + 110 + 2)] / 3
Demand index = (20 + 100 + 3) × y + (14 + 110 + 2) × z
It becomes. However, by setting the variable portions (α, β, y, z), the demand situation of the current month and the previous month is weighted. The door length indicates the length in the height direction of the door material. In addition, the width of the original plate is set to the same size as the width of the door material to be cut.
[0039]
By calculating the demand priority (demand index) of each standard product number in this way, priority management can always be performed in accordance with the demand of the product, and the demand that gradually decreases in this month is corrected by weighting. By doing so, it is possible to manage demand priorities that highly reflect the latest demand trends, and perform highly accurate priority management.
[0040]
By the way, for products whose sales months are less than a predetermined number of months (N months), a monthly average demand is calculated by adding a predetermined correction to the demand trend of the previous month, and a demand priority (demand index) is calculated. I do.
[0041]
Table 2 shows an example where the door part number A is less than a predetermined number of months (three months).
[0042]
[Table 2]

[0043]
in this case,
Standard part A average monthly demand = (15 x (1.0 + γ) + (33 + 0) x (1.0 + α) + (100 + 3) x (1.0 + β) / 3
Demand index = 15 × w + (100 + 3) × y + (110 + 2) × z
It becomes. However, the demand situation of the previous month is weighted by setting the variable part (γ, w).
[0044]
For products for which the number of sales months is insufficient and for which the average demand for a given period cannot be calculated, the average demand is converted based on the outgoing volume of the previous month, so that demand can be prioritized like other products. The degree can be evaluated.
[0045]
The demand priority calculated by the demand priority calculation means 11 as described above is passed to the automatic board preparation plan creation unit 14.
[0046]
On the other hand, based on the order information stored in the order information database D13 and the inventory information stored in the inventory information database D14, the required production quantity calculating means 12 calculates the number of orders and the current number of (General stock) Based on the lower limit stock number, a process of calculating the number of doors required for production is performed.
[0047]
in this case,
The required number (necessary number as a standard part number) = the number of orders on the day + the total number of orders-(the total general stock-the total lower limit inventory)
[0048]
Based on the stock information and order information as shown in Table 3, the required prime numbers for the standard part number (1100092146900) are applied to the above equation. As a result, the order number on the day (2003/01/24) is 6 + 1 and the order total number is 12 Since the total number of general stocks is 16 and the total number of lower limit stocks is 2, the required number is obtained as 1 + 6 + 12- (16-2) = 5.
[0049]
[Table 3]

[0050]
In this way, the necessary production quantity calculation means 12 considers the total number of current stocks (general stock), the total lower limit stock, and the total number of orders (items not yet shipped) in addition to the number of orders on the day, and Is determined, it is possible to calculate the required number of productions on the day in response to fluctuations in inventory status due to unscheduled shipment of inventory items due to shipment delays due to changes in delivery dates or claim reminder.
[0051]
The required production number calculated as described above is passed to the automatic board preparation plan creation unit 14.
[0052]
Next, a plan drawing plan is created from the original plate. Before the plan drawing plan automatic preparation unit 14 performs the final plan plan, the first and second plan preparing means 15a and 15b prepare the first and second plan drawing means. Drafting and making a plan.
[0053]
The first plan creation means 15a for drafting and creating the first boarding plan repeatedly performs the assignment of the original plate and the boarding of the door material in the order of the boarding priority of the door part numbers for the door part numbers requiring production. When the length of the remaining portion of the original plate is shorter than the length of the door material required for production, a door part number that can be cut out is selected based on the demand priority calculated above and plate cutting is performed. Make a plan. The original plate is of a fixed size and the same width as the width of the door material to be trimmed is attracted, and trimming is performed by combining the longitudinal direction of the original plate and the height direction of the door material.
[0054]
That is, as shown in FIG. 2, first, as an extraction process S1 of a production order (production order), ascending order of the number of the original plate for plate picking, descending order of the width of the door material, descending order of the length of the door material, and descending order of the length of the door material, The process of extracting the ascending order is performed, and if there is a production order (production order) (S2), a configuration search for the door product number is performed on the product number master as a configuration master search process S3 to extract the original plate product number.
[0055]
After the original sheet number is extracted, processing S4 is performed to perform original sheet stock allocation processing for sheet removal, and further, a sheet material plan assignment processing for door materials corresponding to the door part number as a product, that is, a door part number plan assignment processing S5 is performed. .
[0056]
The door part numbering plan assignment processing S5 will be described with a plurality of examples.
[0057]
(Example 1)
In this example, the priority order of the board removal is determined from the longest length of the door material. For example, although the door width is the same, as shown in FIG. 3A, the length of the door material is shorter in the order of the product numbers A to D, the required number of the door material of the product number A is 7, and the door material of the product number B is used. Assuming that the required number of door materials is five, the required number of door materials of part number C is four, and the required number of door materials of part number D is three, first, as shown in FIG. The original plate 100 of the length is attracted, and a number of plate members (four in the illustrated example) capable of removing the longest door material of the product number A are assigned to the original plate 100, and the remaining plate portion can be removed. Assign the door material of the product number. In this case, the door material of the door having the shortest product number D is assigned.
[0058]
As shown in FIG. 3 (c), the next original plate 100 is attracted, and the remaining number (3 sheets) of the required number of doors of the product number A are assigned to the original plate 100, and the remaining portions are assigned to the remaining portions. Allocate a door material of a length that can be cut. In this case, two door materials having a product number B having the longest length after the product having the product number A are allocated.
[0059]
Then, as shown in FIG. 3 (d), the next original plate 100 is attracted, and the remaining number (3 sheets) of the required number of doors of the product number B are allocated to the original plate 100, and the remaining portions are assigned to the remaining portions. On the other hand, a door material with a part number of a length that can be boarded is assigned. In this case, two door materials having a product number C and one door material having a product number D are allocated next to the product having the product number B.
[0060]
Then, as shown in FIG. 3 (e), the next original sheet 100 is attracted, and the remaining number (2 sheets) of the required number of doors of the product number C are allocated to the original sheet 100, and the remaining portion is On the other hand, a door material with a part number of a length that can be boarded is assigned. In this case, it is possible to allocate the remaining one board of the length D of the part number D, and further assigns the remaining remaining part to the part number having the highest priority of the free stock selected based on the order of the demand priority. X door materials are allocated for the number of sheets that can be removed (four in the illustrated example).
[0061]
In this way, in the present embodiment, a first boarding plan in which the original sheet allocation and boarding are repeated in the order of the length of the door material is drafted and created.
[0062]
That is, the door material is allocated to the original plate 100 in the door part numbering plan layout allocation processing S5 in FIG. 2, and the length of the surplus (remaining portion) is equal to or longer than a predetermined length (that is, whether or not there is a length that allows the door material to be planed). It is determined in the following step S6 whether or not there is any. If the length is equal to or more than the predetermined length, the same extraction processing as in S1 is performed in the production order extraction processing S7. Until a part number of a door material having a length less than the length of the remainder (remaining portion) is extracted, the processes of steps S6 to S9 in FIG. 2 are repeated. Then, a process of allocating the board material of the door material of the corresponding product number is performed (S10).
[0063]
In this way, in this example, by performing the plate cutting in order from the longest in the height direction of the door material, it is possible to create a plan for a short time in the plate material, and the product number in which the length in the height direction of the door material is long It is possible to create a plan with a higher yield by making a planer from the door in order, and setting the surplus length of the original plate 100 at that time to a length that minimizes the production of free stock door materials. realizable.
[0064]
(Example 2)
In the first example, the priority order for removing sheets from the original sheet 100 is determined based on the length order of the door materials. However, this example is characterized in that the priority order is determined in descending order of the number of sheets required for production.
[0065]
For example, as shown in FIG. 4A, the length of the door material is shorter in the order of the product numbers A to D, the required number of the door material of the product number A is 7, the required number of the door material of the product number B is 5, and the product number is When the required number of door materials of C becomes four and the required number of door materials of part number D becomes three, first, the same original plate 100 as in Example 1 is applied to the most necessary number of door materials of part number B. . In this case, since four door materials of the product number B can be cut out from one original plate 100, three original plates 100 are removed as shown in FIG. Attract to. The two original sheets 100 are allotted with four sheets of door material, and each remaining part has a part number shorter than the length of the part and having a higher free stock priority based on demand priority. For example, the board material of the door material of the product number X is assigned. The length of the remaining portion of the last original sheet 100 to which the boarding of the three door materials corresponding to the product number B is assigned is sufficiently longer than the length of the door material of the product number A, which is the next most necessary number, The remaining parts are assigned to the door material of the product number A. In this case, one sheet of the door material of the product number A can be removed. The remaining portion becomes a surplus portion a from which the door material cannot be removed.
[0066]
Next, two original plates 100 are attracted in correspondence with the removal of the door material of the product number A. In this case, as shown in FIG. 4C, four door materials can be cut out from one original plate 100, and the length of the remaining portion when the four door materials of the product number A are assigned is cut out. In order to correspond to the length that one door material of the part number D can be cut out, the remaining part is assigned the plate material of the door material of the part number D. Then, the length of the remaining portion of the original plate 100 to which the two door materials of the part number A are assigned can be removed. Allotment of door material of part number C is assigned. The free stock priority order based on the demand priority is high for the remaining part, and a part number of a length that can be cut out from the remaining part, for example, the boarding of the door material of the part number X is assigned.
[0067]
As shown in FIG. 4 (d), since the required number of the door materials having the product number C of four has already been allocated to the three boards as described above, the remaining one board is allocated. , One original sheet 100 is attracted to the original sheet 100, and one sheet of the door material of the product number C is assigned to the original sheet 100. Since the length of the remaining portion of the original plate 100 is sufficiently long, the required number is three, and the remaining two door materials of the product number D to which the one-board cutting has already been allocated are allocated. Then, the free stock priority order based on the demand priority is higher for the remaining parts that are generated, and a part number of a length that can be removed from the remaining parts, for example, four pieces of door materials of the part number X are assigned. Since there is no door material having a product number corresponding to the length of the last remaining portion, the last remaining portion is a surplus portion b.
[0068]
As described above, in this example, by performing the board cutting by assigning priorities to door materials having a large required number of door materials, it becomes possible to create a large number of board-cutting plans capable of producing lots (collectively cutting) with the same part number. In addition, it is possible to create a plan for improving the productivity.
[0069]
Next, a description will be given of an example of a method of determining a free stock selection order in the case of allocating door stock of free stock to the remaining portion of the original sheet 100 in the above Examples 1 and 2.
[0070]
(Example I)
In this example, the length of the remaining portion (remaining portion) of the original plate 100 is shorter than the length of the door materials of all the product numbers required for production in the planing plan allocating process performed by the first plan creating means 15a. When the length is equal to or longer than the shortest door material (predetermined length or longer) (S1 in FIG. 5), the process proceeds to the free stock door extraction process S2. Based on the information from the stock information database D14, the stock days [= (number of free stocks / monthly average demand)] of the free stock quantity [= (current stock quantity-order reserved stock-lower limit stock)] is obtained, The order of selection as free stock (ascending order of free stock in days) is determined.
[0071]
Then, the first plan making means 15a checks the presence or absence of a free stock part number based on the selection order (S3). If there is a part number, the length of the remaining part (remaining part) of the original plate 100 and the door material of the part number are checked. (S4), and if the length of the door material is less than the length of the remaining portion, the processing for allocating the board plan of the door material of the free stock part number (S5) is performed as in the above-described example 1 or 2. is there. If the length of the door member exceeds the length of the remaining portion, the process returns to S1. If the length of the remaining portion (remaining portion) of the original sheet 100 is less than the predetermined length, or if there is no part number in the free stock part number check, the plate removal for the original sheet 100 ends.
[0072]
(Example II)
This example is an example in which if the number of free stock days of the target product number for which the board stocking corresponding to the free stock exceeds a predetermined reference date is not performed, the board stocking is not performed as the free stock. It is possible to perform operation management based on a certain number of days of inventory according to the monthly average demand, and it is possible to suppress free stock from becoming overproduced.
[0073]
FIG. 6 shows a flowchart of the free stock removal in the present embodiment. In the illustrated example, a free stock days check (S6) is added to the flowchart of FIG.
[0074]
(Example III)
In this example, instead of the stock days in Example II, if the free stock number exceeds a predetermined reference number, the stocking is not performed as free stock. It is possible to prevent the absolute amount of the free stock number of the product number, for which the free stock days are reduced because it is very large, from increasing, and it is possible to keep the stock space for storing the products within a certain amount.
[0075]
(Example IV)
FIG. 7 shows a flowchart of the free stock of the present embodiment. In the illustrated example, the free stock quantity check (S7) is added to the flowchart of FIG.
[0076]
In the above examples I to c, the planing of the door material having the product number of the free stock is performed according to the priority order selected by the number of days of the free stock (ascending order). In such a case, the height direction of the door material is used. Long doors are less likely to be picked up as free inventory. Therefore, in this example, a specific free stock target product number is determined in advance, and when the length of the remaining portion (remaining portion) of the original plate 100 becomes shorter than the height direction of all the door materials necessary for production, the first specification is performed. It is possible to increase the free stock for a specific product number by performing board removal with the highest priority on the free stock target product numbers.
[0077]
FIG. 8 shows a flow chart of the free stock removal in the case of the present example. In this illustrated example, the free stock availability check S8 and the free stock are possible in the flowchart of FIG. In this case, a free stock door part number board layout plan allocating process S9 is added.
[0078]
Thus, the first plan making plan is created by the first plan making means 15a by using the planing plan allocating method of Example 1 or 2 using the plan stocking method of any of the above-described Examples I to III. The created first planing plan is stored in the first planing plan result storage database D15a.
[0079]
Next, the creation and preparation of a second planing plan by the second plan creation means 15b will be described.
[0080]
First, the second plan creator 15b applies the original plate 100 for each product number to the door materials of the product numbers that need to be produced, repeats the stripping of the door materials, and repeats the process for all the product numbers that need to be produced. After the sheet removal for the door material is completed, the length of the remaining part (remaining part) is longer than a predetermined length. For the original sheet 100, the sheet removal is integrated according to the integration of the sheet removal plan or the priority order indicated by the above-mentioned demand priority information. A pickable part number is selected, and a planner plan is drawn up as a second planer plan using the door material of the part number as a free-stock door material.
[0081]
Next, a description will be given of a plurality of examples of the planing method of the second plan making means 15b.
[0082]
(Example i)
The second plan making means 15b of this example, after finishing the required number of plate-cuttings for the door materials of all the product numbers that need to be produced, sets the number of original plates of the same plate-cutting pattern to the predetermined number of sheets. In the above case, the remaining portion (remaining portion) of the original plate, which did not have the same pattern, is subjected to the plate removal for the door material of the above-mentioned part number A, and the plate removal pattern of the original plate is compared with another original plate. Plan and create a plan with the same planing pattern.
[0083]
For example, when 26 door materials of the product number A are required, if the original plate 100 capable of removing four door materials of the product number A is used, it is necessary to attract seven original plates 100 as shown in FIG. 9A. . In this case, the number of original plates 100 having the same boarding pattern is six as shown. Here, assuming that the predetermined number is six in advance, the number is six in the illustrated example, and the second plan creating means 15b is to plank two door materials having the planing part number A7. The remaining portions (remaining portions) of the second original sheet 100 are divided into two pieces of the door material of the product number A so that the same pattern as the other six original sheets 100 is obtained. Door material is made free stock.
[0084]
Now, in each of the original sheets 100, a remaining portion (remaining portion) c is generated at the end portion even when four plates are removed, and the length of the remaining portion c is as shown in FIG. 9B. If the predetermined length is equal to or more than the predetermined reference value corresponding to the lower limit length of the door material that can be cut out, the boarding of the door material of the part number Y that can be cut out is allocated to the remaining portion c. Free stock.
[0085]
In other words, in the case of FIG. 9, it is possible to allocate four door materials of part number A and one door material of part number Y from one original plate 100.
[0086]
By the way, when the required number of door materials of the product number A is 18, five original plates 100 are used as shown in FIG. 10, and four of the original plates 100 have the same pattern. In this case, since the number of the originals 100 having the same boarding pattern is smaller than the predetermined number 6, the second plan creating unit 15 b determines the remaining portions of the original 100 on which the door materials of the part number A for two sheets are to be boarded. The planing is allocated according to the selection order determined based on the demand priority information. In this case, a door material having a higher priority, for example, a door material having a product number C is allocated, and a door material having a product number D is further allocated. Further, the door material of the above-mentioned part number Y, which can be removed at the remaining portion c at the end of each original plate 100, may be subjected to plate removal, and this door material may be made a free stock.
[0087]
As described above, in the present example, when the number of the originals 100 having the same boarding pattern is equal to or more than a predetermined number (six in the example), the number of the boarding assigned to the remaining portion of the original 100 that does not become the same boarding pattern. Then, a second boarding plan capable of improving the yield and the productivity is created by allocating the boarding of the door material having the same product number.
[0088]
(Example ii)
The second plan making means 15b of the present example, after completing the necessary number of plate-cuts for the door materials of all the product numbers that need to be produced, sets the remaining portion (remaining portion 8) of the original sheet 100 as free stock. In allocating the door material of the product number based on the demand priority, there is a predetermined value (for example, 100 or more) of the demand priority of the product number requiring the production in which the layout is previously allocated to the original plate 100. For example, the board layout of the door material of the part number is allocated, the door material is set as free stock, and if it is less than the predetermined value, the board layout of the door material of the part number selected in order of demand priority is drafted.
[0089]
FIG. 11A shows a case where a door material of a free stock is boarded for a remaining portion (remaining portion) of the original plate 100 in which a door material of a product number A with a demand priority of 150 is taken out. In this case, since the demand priority of the door material of the part number A is equal to or more than a predetermined value (for example, 100), the boarding of the door material of the part number A is allocated to the remaining part as much as possible (lotted). Then, a part number is selected in the order of the demand priority for the portion remaining after this boarding, and the boarding of the door material of the part number, for example, the part number Z, is performed.
[0090]
FIG. 11B shows a case where a door material of free stock is boarded for a remaining portion (remaining portion) of the original plate 100 in which a door material of a product number B having a demand priority of 10, for example, is boarded. In this case, since the demand priority of the door material of the product number B is less than the predetermined value (100), the product number is selected in the remaining portion in order of the demand priority, and the product number, for example, the door material of the product number Z having a higher priority order is selected. Board layout is performed, and in the remaining portion, a door material having a higher priority order, for example, a door material of V, in which the length of the door material is shorter than the length of the portion, is performed.
[0091]
Further, FIG. 11 (c) shows a case where a door material of free stock is boarded with respect to the remaining portion (remaining portion) of the original sheet 100 in which the door material of the product number C whose demand priority is, for example, 120, In this case, since the demand priority of the door material of the product number C is equal to or more than the predetermined value (100), the remaining portions are allocated as many as possible (three sheets in the illustrated example). ). Then, a part number is selected in the order of demand priority for a portion that is further left after the board cutting, and a board member of the door material of the part number is allocated. In the illustrated example, since the length of the remaining portion is not longer than a predetermined length, the board layout is not performed.
[0092]
FIG. 11D shows a case where a door material of a free stock is boarded for the remaining portion (remaining portion) of the original plate 100 in which the door material of the product number D whose demand priority is 70, for example, In this case, since the demand priority of the door material of the product number D is less than the predetermined value (100), a product number, for example, a product number Z is selected in the remaining portion in the order of the demand priority, and the plate material of the door material of the product number Z is selected. Allotment is performed, and in the remaining portion, the door material having a shorter length of the door material than the length of the portion and having a higher priority in the product number, for example, a door material of V is subjected to plate cutting.
[0093]
In this manner, in this example, for a part number with a high demand priority, a board preparation plan that can improve the yield and the productivity by continuously taking the same part number, that is, by making the board production for lot production, is prepared. I do.
[0094]
(Example iii)
In this example, we assume a plan for drawing a plate by attracting a plate for each product number that requires production, and a plan for the plan where the length of the remaining part of each plate is equal to or greater than a predetermined length. Then, the planner plans are combined and integrated so that the length of the remaining portion is minimized, and the integrated result is finally created as a planer plan that minimizes the length.
[0095]
FIG. 12 shows that the required number of door materials of, for example, 13 parts number A, the required number of, for example, three plate materials of B, the required number of, for example, three plate materials of C, and the required number of, for example, three plate materials. FIG. 11 shows a flow when drafting a board plan for the door material of the product number D. In this example, the second plan creating unit 15b firstly allocates four original plates 100 to the product number A, A plan for removing the 13 door materials of the product number A is created as shown in FIG. Similarly, one original plate 100 is attracted to each of the product numbers B to D, and a plan for removing three door materials of the product numbers B to D for each original plate 100 is shown in FIGS. 12B to 12D. Create as follows. 12 (a) to 12 (d) so that the length of the remaining portion from the end portion (right end in the drawing) of the original sheet 100 becomes the minimum from the plate removal plan in which the length of the remaining portion is equal to or more than the predetermined reference value L. )), A process of integrating the board plan of each of the product numbers A to D is performed. In this case, the combinations in which the lengths of the remaining portions of the original plate 100 are the smallest are extracted by combining the planing plans of FIGS. 12 (a) to 12 (d). In this case, the combination is performed so that door materials having the same product number can be continuously produced, that is, a lot can be produced.
[0096]
In the case of FIG. 12, the door material of the part number B having the longest length of the inner material of the door materials of the part numbers B to D is provided on the remaining portion of the original plate 100 in which only one door material of the part number A is removed. The length of the remaining portion of the original plate 100 can be minimized by combining the planing plan of FIG. Also, by combining the plan of the door material of the part number D of FIG. 12C with the plan of the door material of the part number C of FIG. 12) and FIG. 12D, it is possible to create a plan that is shorter than the plan shown in FIG. 12D as shown in FIGS. Thus, the drafting planning means 15b drafts and prepares the planing plan obtained by integrating the planing plan as described above as the final planing plan. This makes it possible to reduce the total number of the original sheets 100 used for sheet-pickup, and to make a sheet-pickup plan in which productivity is improved together with lot production.
[0097]
(Example iv)
In the above example iii, a plan for making a plan that minimizes the length of the remaining portion of the original sheet 100 is drafted and created by integrating the plan for plan, but in this example, for example, the required number of 13 When planning a boarding plan for a door material of A, a required number of 3 plate materials of B, a required number of 3 plate materials of C, and a required number of 3 plate materials of D, First, the second plan creator 15b draws four originals 100 against the part number A in the same manner as described above, and prepares a planer plan for 13 door materials of the part number A as shown in FIG. I do. Similarly, one original plate 100 is attracted to each of the product numbers B to D, and a plan for removing three door materials of the product numbers B to D for each original plate 100 is shown in FIGS. Create as follows. 13 (a) to 13 (d) are integrated so that the length of the remaining portion is minimized from the length of the remaining portion of each original plate 100 that is longer than a predetermined length. Perform processing. In this case, the combinations in which the lengths of the remaining portions of the original plate 100 are minimized are extracted by combining the planing plans of FIGS. 13 (a) to 13 (d). In this case, the combination is performed so that door materials having the same product number can be continuously produced, that is, a lot can be produced. Up to this point, the process is the same as in Example iii, but in this example, the length of the remaining portion of the original sheet 100 that is further generated in the planing plan obtained by integration as shown in FIGS. If the length is longer than the value L, the free stock is calculated as the free inventory calculated based on the number of free days [= (the number of current stocks−the number of stocks reserved for orders−the minimum number of stocks)] [= the number of free stocks / the average monthly demand). According to the selection order, the free stocking is further performed in ascending order of stock. In the case of FIG. 13 (e), one door material of the part number A or B required to be produced can be cut out by one sheet, and two door materials of the part number E which do not need to be produced in the present plan are prepared. I can take it. Similarly, in the case of FIG. 13F, one of the door materials of the product number D or one of the door materials of the above-mentioned product number E which needs to be produced can be boarded.
[0098]
The second planing plan result is created by the second plan creating means 15b by any of the methods of Examples i to iv described above, and stored in the second planing result storage database D15b.
[0099]
In the production plan creation system of the present invention, one of the first and second planing plan results stored in the databases d15 and D15b is determined as a final planing plan by the planing plan evaluation means 16. Is performed based on the flowchart shown in FIG.
[0100]
In other words, the planing plan evaluation means 16 captures the yield, productivity (machining time, number of types) data stored in the planing evaluation reference information database D16 and the number of days of stock data from the stock information database D14, and obtains the first planing plan result. The data is totaled for each of the color and pattern and the door width (original plate width) with respect to and the second planing plan result (S1).
[0101]
Specifically, the evaluation item data includes the number of used original sheets, the used original length (because there are some lengths for the same original sheet width), the number of door materials (including the number of free stock doors), and the number of doors. Material free stock production quantity (free stock quantity / monthly average demand per door standard part number), door material production length (product size of each member), production time (processing program setting time and processing for each boarding plan) Aggregate time and setup work time <Program set time is added each time the pattern of the board setup plan is changed (zero if the pattern is the same. Also, machining time is calculated by cutting times x average time. , Calculated by the required number of original sheets x average loading time, the number of production door materials x average unloading time), and the number of machining program settings (preset standard machining pattern <single part number cut, frequently used machining pattern>) Set number of times to the program), to aggregate the processing varieties number (variety number of door material to be cut from a single original sheet aggregate <size unit>).
[0102]
In the next step S2, the evaluation value is obtained by multiplying the yield, the processing time, the number of types, and the number of days of stock for each color, pattern, and door width by a predetermined weighting coefficient previously stored in the board evaluation evaluation information database D16. calculate. Then, in the next step S3, the evaluation value is compared for each color pattern and door width, and a planing plan to be adopted for each color pattern and door width is determined.
[0103]
Here, the following are specific examples of the evaluation value for each color and pattern of the original plate and each original plate width.
[0104]
Yield = Length of door material production / Length of original plate used
Free inventory production ratio = Door material free inventory production number / Door material production number
Free stock days = Free stock of door materials / Average monthly demand
(Inventory days evaluation is calculated not only from the production on the day but also from the free inventory at the current stage.)
Time productivity = Number of door materials produced / Production time
Number of times of program = Machining program setting times / Number of original sheets
Number of cut products = Number of processed products / Number of original plates used
The following are adopted as the overall evaluation value for performing the overall evaluation and the current weighting coefficient.
[0105]
Comprehensive evaluation value = Yield x α + (monthly standard of free inventory ratio / free inventory production ratio) × β + (monthly standard of time productivity / production time) × γ
The monthly reference of the free inventory production ratio sets a reference value in advance based on monthly average information of the free inventory production ratio. The time productivity monthly reference sets a reference value in advance based on monthly average information of time productivity. In the above expression of the evaluation value, the reference value of each evaluation data of the yield, the free stock, and the time productivity is converted into 1.0 and corrected by the coefficients (α, β, γ).
[0106]
Weighting factor (current setting value)
α = 6.0
β = 3.0
γ = 1.0
As the plan, a plan with a high overall evaluation value for each color and pattern of the base plate and the width of the base plate is adopted. The setting of the weighting coefficient is adjusted as follows according to the production situation and the stock situation.
[0107]
When the yield is low, the α value is increased. If there is a lot of free stock, the β value is increased. Then, if necessary, the α value is reduced. When the productivity is low, the γ value is increased. Then, if necessary, the α value is reduced.
[0108]
The planing plan determined to be adopted based on the overall evaluation value and the weighting as described above is stored in the storage device 3 (S4). Thereafter, before actual production, a production instruction sheet of a predetermined format is created from the board plan stored in the storage device 3 and output from the output device 4 such as a printer.
[0109]
By storing the yield, productivity, weighting factor, and the like serving as the boarding evaluation reference information in the database D16, the evaluation criteria can be changed, and the boarding evaluation is performed for each color, pattern, and door width according to the boarding evaluation value. By adopting a planner plan with a better result, a planer plan that realizes a high yield in consideration of both demand and productivity can be created and provided. Further, by storing the adopted planing plan in the storage device 3, it is possible to point out the adopted planing plan at a necessary timing.
[0110]
The present invention can of course be applied to members which need to be cut out in addition to door materials for box-shaped products.
[0111]
【The invention's effect】
The invention of the production plan creating method according to claim 1 is a method for manufacturing a door material from a fixed-size original plate having the same width as the width of the door material of the product to be trimmed such that the height direction of the door material is the longitudinal direction of the original plate. In a production plan creation method for creating a board plan to be used when cutting, a product based on master information read from a database unit that stores master information on demand frequency, master information on each product to be produced, and stock information on the product. Calculating the demand priority of this product, calculating the required number of products from the order information of the current ordered product and the stock information of the product stored in the database section, For the door material of the product that became the target, the assignment of the original plate and the removal of the door material were repeatedly performed in the order of the priority of the plate removal of the door material, and the length of the remaining part of the original plate in the plate removal state required production. Do When the dimensions of all the door materials cannot be removed, the door materials of the products that can be removed are selected according to the order of the demand priority calculated by the demand priority calculation means, and the remaining parts of the original plate are selected. The first plan creation process of automatically creating the first planing plan that performs planing from parts, and the assignment of original plates for each product part number for door materials of products that need to be produced by this order Repeatedly, and removing the door material, after performing the removal of the door material of all the products that need to be produced, the remaining part By selecting a door material of a product that can be boarded according to the order of the demand priority calculated by the demand priority calculation means by integrating the planing plan created by the boarding for each part number, The second to remove the board from the remaining part of the original sheet For the second plan creation process of automatically creating a plan and the plan plan created by the first and second plan creation processes, at least the yield is obtained for each color and pattern of the door material and the width of the door material. And the number of days in stock, and the final evaluation of the plan to be adopted. There is an effect that a plan can be created in a short time.
[0112]
The invention of the production plan creating system according to claim 2 is based on master information on demand frequency, master information on each product to be produced, and stock information on products, and a master unit read from the database unit. Priority calculation means for calculating the demand priority of a product, and required production quantity calculation for calculating a required production quantity from the order information of the current ordered product and the stock information of the product stored in the database unit. Means and the door materials of the products that need to be produced by this order. When the length of the part becomes a dimension that cannot be cut out for all the door materials that need to be produced, plate cutting is performed according to the order of demand priority calculated by the above demand priority calculation means. First plan creating means for automatically creating a first planing plan for selecting a functional material door material and performing planing from the remaining portion of the original plate, and a door for a product which has become necessary due to this order For each part of the product, the process of applying the original plate and removing the door material is repeated for each part number of the product, and after removing the door material for all the products that need to be produced, the length of the remaining part is For the original plate in which the plate size is larger than the predetermined size, the plate plan created by the plate cutting for each part number is integrated, or according to the order of the demand priority calculated by the demand priority calculating means, By selecting a door material of a product that can be removed, a second plan creation means for automatically creating a second boarding plan for performing board removal from the remaining portion of the original sheet, and first and second plan creation means are provided. For each plan to be created, the color and pattern of the door material It is equipped with a board removal plan evaluation means that evaluates at least the yield, productivity, and the number of days in stock for each width of the door and door material, and automatically determines the final plan to be adopted. There is an effect that it is possible to automatically and quickly create a board plan with high yield and high productivity in consideration of the production of negative R-stock.
[0113]
According to a third aspect of the present invention, in the invention of the second aspect, the demand priority calculating means determines a product number of each product to be cut out by using a color pattern of a door material, an original plate width, and a height of the door material. Calculates the monthly average demand in the unit of standard part number grouped by direction, corrected by applying a predetermined weighting to the demand in the previous month and the average demand in the past predetermined number of months to emphasize the demand trend in the previous month However, since it is a calculating means for determining the demand priority from the door material of the product having a large monthly average demand, it is possible to always carry out a board plan based on the priority linked to the demand of the product. Since the priority can be managed in a manner that greatly reflects the tendency, it is possible to create a board plan based on the priority managed with high accuracy.
[0114]
According to a fourth aspect of the present invention, in the invention of the second aspect, the demand priority calculating means determines a product number of each product to be boarded by a color and a pattern of a door material, an original plate width, and a height of the door material. For each standard part number grouped by direction, for products whose sales months are less than the predetermined number of months assumed in advance, calculate the monthly average demand amount corrected by performing a predetermined weighting that emphasizes the demand trend of the previous month, Since it is a calculating means for determining the demand priority from the door material of a product having a large monthly average demand, a product having insufficient sales months and for which the average demand for a predetermined number of months cannot be calculated, the demand trend of the previous month. There is an effect that it is possible to create a plan for taking a plan based on the demand priority based on the monthly average demand calculated based on the plan.
[0115]
According to a fifth aspect of the present invention, in the invention according to the second or third aspect, the required production quantity calculating means includes the order quantity, the current stock quantity, and the lower limit stock quantity of each product ordered in a predetermined period. It is a calculation means that calculates the number of door materials required for production based on the number, so it also responds to changes in inventory status due to unscheduled delivery of inventory items due to shipment delays due to changes in delivery dates or complaints, reminder etc. There is an effect that it becomes possible to create a board plan based on the required production quantity.
[0116]
According to a sixth aspect of the present invention, in the invention according to any one of the second to fifth aspects, the first plan creating means performs board trimming from an original sheet for door materials of products requiring production. In this case, the first planner plan is created by deciding the prioritizing order of the door materials in the order of the length in the height direction, so that the planner plan can be created in a short time, and the remaining portion of the original sheet can be prepared. Since the length can be reduced, there is an effect that it is possible to minimize the production of the door material for free stock and to create a plan to increase the yield.
[0117]
According to a seventh aspect of the present invention, in the production plan creating system according to any one of the second to fifth aspects, the first plan creating means performs board trimming from an original sheet for door materials of products requiring production. At this time, the first boarding plan is created by deciding the priority of the boarding in order from the door material with the largest number of required materials. There is an effect that it becomes possible to create a plan for taking a sheet.
[0118]
The production plan creation system according to claim 8 is the invention according to claim 6 or 7, wherein the first plan creation means repeatedly performs the assignment of the original plate and the removal of the door material in the order of the removal priority, When the length of the remaining part of the original sheet in the board-cutting state is such that the door material of all the products necessary for production cannot be cut out, subtract the order reserved inventory quantity and the lower limit inventory quantity from the current inventory quantity. A first stocking plan in which the order of selection as free stock is determined based on the number of days of stock with respect to the number of free stocks determined in accordance with the above, and door materials for free stock are trimmed from the remaining portion of the original sheet based on the above selection order. Since it is created, there is an effect that it is possible to create a boarding plan in which door materials produced as free stock can be matched to the demand.
[0119]
According to a ninth aspect of the present invention, in the invention of the eighth aspect, when the number of free stock days exceeds a predetermined reference number of days, plate removal from the remaining portion of the original sheet is stopped. There is an effect that it is possible to create a board plan that suppresses excessive production of door materials.
[0120]
According to a tenth aspect of the present invention, in the invention of the eighth aspect, when the number of the free stocks exceeds a predetermined reference number, the plate removing from the remaining portion of the original plate is stopped. Can prevent the phenomenon that the absolute amount of free stock of door materials corresponding to the product number whose product demand is very large and the number of free stock days is small increases, and as a result, the stock space is kept within a certain amount There is an effect that it becomes possible to create a plan for taking a sheet.
[0121]
An invention of a production plan creating system according to claim 11 is the invention according to claim 6 or 8, wherein the first plan creating means repeatedly performs the assignment of the original plate and the plate removal of the door material in the plate removal priority order, If the length of the remaining part of the original sheet in the board removal state is such that the door material of all the products necessary for production cannot be removed, the door material of the product number of the free stock target specified in advance is Since the first planing plan for performing planing from the remaining part of the original plate is created, a free stock of a specific product number corresponding to a door material having a long length in the height direction that is difficult to be planed is intentionally prepared as free stock. There is an effect that it is possible to create a plan for producing boards.
[0122]
According to a twelfth aspect of the invention, there is provided the production plan creation system according to any one of the second to eleventh aspects, wherein the second plan creation means is configured to select a door material of a product requiring production from a fixed-size original plate to a plate. When performing the picking, after repeatedly removing the door material from the original plate for each product part number and performing the board removal for all the product numbers that require production, the original sheet with the same boarding pattern is determined in advance If the number of sheets is equal to or greater than a predetermined number, the door material of the product having the same part number as the part number to be cut out of these base sheets is cut out, and the remaining parts of the base sheet having a different boarding pattern are assigned to the original sheet. Since the second planing plan in which the door material of the product having the same part number and the door material of the product is used for free stocking is prepared, it is possible to prepare a planing plan that can increase the yield and the productivity.
[0123]
According to a thirteenth aspect of the invention, there is provided the production plan creation system according to any one of the second to eleventh aspects, wherein the second plan creation means is configured to convert a door material of a product requiring production from a fixed-size original plate to a plate material. When performing the picking, after repeatedly removing the door material from the original plate for each product part number and performing plate removal for all product numbers that require production, the demand priority of the part numbers assigned to the original plate In the case where the value is equal to or greater than a predetermined value, a second planing plan is prepared in which a door material of a product having the same part number as that of the part number already allocated to the remaining part of the original sheet is planed as a free stock for the free stock. There is an effect that it is possible to continuously produce a door material of a product, and to create a board plan that can improve yield and productivity.
[0124]
According to a fourteenth aspect of the present invention, in the production plan creating system according to any one of the second to eleventh aspects, the second plan creating means is configured to convert a fixed-size original plate to a door material of a product requiring production. When removing the door material, repeat the removal of the door material from the original plate for each product part number. The above-mentioned plan is integrated to create a plan that minimizes the length of the remaining part of the original sheet, and a second plan is created. The continuous production has the effect that it is possible to create a plan for planning that can improve productivity.
[0125]
According to a fifteenth aspect of the invention, there is provided the production plan creation system according to any one of the second to eleventh and fourteenth aspects, wherein the second plan creation means includes a fixed-size original plate for a door material of a product requiring production. When performing board removal from the original product, repeat the board removal of the door material from the original sheet for each product number, and after performing the board removal for all the product numbers that require production, the length of the remaining part is the specified dimension For the above original sheets, the order of selection as free inventory is determined based on the number of days of stock for the free inventory number obtained by subtracting the order reserved inventory number and the lower limit inventory number from the current inventory number. Since a second planing plan is made to plan door materials for free stock based on the above selection order, production of door materials that become free stock is suppressed, and continuous production of the same part number improves yield and productivity. Can be improved There is an effect that it becomes possible to create a preparative plan.
[0126]
The production plan creation system according to claim 16 is the invention according to any one of claims 2 to 15, wherein each of the yield, the productivity, and the number of days in stock for each of the color and pattern of the door material and the door width is used as an evaluation criterion for the planing plan. A database unit storing information is provided, and the planing plan evaluation means collects the yield, productivity, and number of days of stock for each of the first and second planing plans by color and pattern of the door material and door width. Calculate the evaluation values for the totaled yield, productivity, and number of days in stock, compare the evaluation values for each color and pattern of the door material and the width of the first and second planning plans, and determine the plan to finally adopt. Therefore, since a plan view plan can be determined by an evaluation in consideration of both demand and productivity for each color and pattern of a door material and a door width, there is an effect that a plan view plan that realizes a high yield can be created.
[0127]
According to a seventeenth aspect of the present invention, in the invention of the sixteenth aspect, when the evaluation value is calculated, the weight is corrected by performing a predetermined weighting, so that an evaluation value corresponding to the stock and the production situation can be obtained.
[0128]
Since the invention of the production plan creating system of claim 18 is the invention according to any one of claims 2 to 17, it has a storage medium for storing the data of the board plan finally determined by the board plan evaluation means. It becomes possible to take out the finally determined plan at the required timing.
[Brief description of the drawings]
FIG. 1 is an overall system configuration diagram of the present invention.
FIG. 2 is a flowchart for explaining the operation of a first plan creation unit according to the first embodiment;
FIG. 3 is an explanatory diagram of a first example of a door part number board plan allocating process in the first plan creator according to the first embodiment;
FIG. 4 is an explanatory diagram of Example 2 of a door part number board layout plan allocating process in the first plan creator in the embodiment.
FIG. 5 is a flowchart for explaining Example I of a method for determining a selection order of free stock in the first plan creating means of the Embodiment.
FIG. 6 is a flowchart for explaining Example II of a method of determining a selection order of free stock in the first plan creating means according to the embodiment.
FIG. 7 is a flowchart for explaining Example III of a method of determining a selection order of free stock in the first plan creating means according to the embodiment.
FIG. 8 is a flowchart for explaining an example IV of a method of determining a selection order of free stock in the first plan creating means according to the embodiment.
FIG. 9 is an explanatory diagram of a method i of a planing planning method employed in the second planning means according to the first embodiment;
FIG. 10 is an explanatory diagram of another method i of the planing planning method adopted by the second planning means of the above.
FIG. 11 is an explanatory diagram of a method of an example ii of a planing planning method adopted by a second planning unit according to the embodiment.
FIG. 12 is an explanatory diagram of one method of an example iii of a planing planning method adopted by the second planning unit according to the first embodiment;
FIG. 13 is an explanatory diagram of a method of an example iv of a planing planning method adopted in the second plan creating means of the above.
FIG. 14 is a flow chart for explaining the operation of the above-described sheet removal plan evaluation means.
[Explanation of symbols]
1 Production planning system
2 Production management system
3 Storage device
4 Output device
5 Input device
10 Computer section
11 Demand priority calculation means
12 Production number calculation means
13 Sheet taking parameter setting means
14 Itabori Planning Automatic Creation Department
15a First plan creation means
15b Second plan making means
16 Ittori plan evaluation means
D11 Demand frequency master database
D12 Part number master database
D13 Order information database
D14 Inventory information database
D15a First storage plan storage database
D15b Second planing plan result storage database
D16 Itatori Evaluation Criteria Information Database
D21 Inventory information database
D22 Order information database
D23 Entry / exit history information database

Claims (18)

Creation of a production plan to create a board plan for cutting a door material from a base sheet of the same width as the door material of the product to be cut, so that the height direction of the door material is the longitudinal direction of the original sheet In the method,
A process of calculating the demand priority of the product based on the master information on the demand frequency, the master information on each product to be produced, and the master information read from the database unit storing the stock information of the product,
Calculating the required production quantity from the order information of the ordered product and the stock information of the product stored in the database unit;
For the door materials of the products that need to be produced as a result of this order, we will repeat the assignment of the original plate and the removal of the door material in the order of door material removal priority, and the length of the remaining part of the original plate in the plate removal state However, when the dimensions of all door materials requiring production cannot be removed, door materials of products that can be removed according to the order of demand priority calculated by the demand priority calculation means are used. A first plan creation step of automatically creating a first board removal plan for selecting a board and performing board removal from the remaining portion of the original sheet;
For the door materials of the products that need to be produced by this order, we will repeat the assignment of the original plate and the removal of the door material for each product number, and the doors of all the products that need to be produced After performing the planing for the material, for the original sheet in the planed state where the remaining part length is larger than the specified dimension, integrate the planing plan created by the planing for each of the above product numbers, or according to the demand priority. Second plan creation for automatically creating a second planing plan for performing planing from the remaining portion of the original sheet by selecting door materials of products that can be planed according to the order of demand priority calculated by the calculating means. Process
For the planing plan created by the first and second plan creation processes, at least the yield, productivity, and the number of days of stock are evaluated for each color and pattern of the door material and the width of the door material, and finally adopted. And a step of evaluating a plan to determine the production plan. A production plan that automatically creates a boarding plan to be used when cutting door material from a fixed-size original sheet with the same width as the door material width of the product to be boarded so that the height direction of the door material is the longitudinal direction of the original sheet. In the creation system,
Master information about the frequency of demand and production target when cutting door material from a standard sheet of the same width as the width of the door material of the product to be trimmed so that the height direction of the door material is the longitudinal direction of the original sheet A database unit storing master information and product inventory information for each product,
When cutting out door materials for ordered products, a database unit that stores master information about demand frequency, master information about each product to be produced, and product inventory information,
A demand priority calculating means for calculating a demand priority of the product based on the master information read from the database unit;
A required production quantity calculating means for calculating a required production quantity from the order information of the ordered product and the stock information of the product stored in the database section;
For the door materials of the products that need to be produced as a result of this order, we will repeat the assignment of the original plate and the removal of the door material in the order of door material removal priority, and the length of the remaining part of the original plate in the plate removal state However, when the dimensions of all door materials requiring production cannot be removed, door materials of products that can be removed according to the order of demand priority calculated by the demand priority calculation means are used. A first plan preparation means for automatically preparing a first plan view plan for selecting a plan view and performing planing from the remaining portion of the original sheet;
For the door materials of the products that need to be produced by this order, we will repeat the assignment of the original plate and the removal of the door material for each product number, and the doors of all the products that need to be produced After performing the planing for the material, for the original sheet in the planed state where the remaining part length is larger than the specified dimension, integrate the planing plan created by the planing for each of the above product numbers, or according to the demand priority. Second plan creation for automatically creating a second planing plan for performing planing from the remaining portion of the original sheet by selecting door materials of products that can be planed according to the order of demand priority calculated by the calculating means. Means,
For the planing plan created by the first and second plan creating means, respectively, at least the yield, productivity, and the number of days of stock are evaluated for each color and pattern of the door material and the width of the door material, and finally adopted. A production plan creation system, comprising: a planner plan evaluation means for automatically determining creation. The demand priority calculating means is a unit of a standard product number in which a product number of each product to be boarded is grouped according to a color pattern of a door material, a width of an original plate, and a height direction of the door material. Calculate the corrected monthly average demand by performing a predetermined weighting to emphasize the demand trend of the previous month with respect to the average demand of a predetermined number of months, and determine the demand priority from the door material of the product with the higher monthly average demand 3. The production plan creation system according to claim 2, wherein the calculation means performs calculation. The demand priority calculating means is configured such that the number of sales months is determined in advance for each standard part number in which the part numbers of the products to be cut are grouped according to the color pattern of the door material, the width of the original plate, and the height direction of the door material. For a product having less than a number of months, a predetermined monthly weighting that emphasizes the demand tendency of the previous month is calculated to calculate a corrected monthly average demand, and a calculation for determining a demand priority from door materials of a product having a large monthly average demand is performed. 3. The production plan creation system according to claim 2, wherein the system is a means. The required production quantity calculating means is a calculating means for calculating the number of door materials required for production based on the number of orders for each product number ordered during a predetermined period, the current stock quantity, and the lower limit stock quantity. 4. The production plan creation system according to claim 2, wherein: The first plan making means determines the priority of door material removal in descending order of length in the height direction when performing plate removal from an original plate for door materials of products requiring production. The production plan creation system according to any one of claims 2 to 5, wherein the board plan is created. The first plan making means, when performing board trimming from an original plate for door materials of products that need to be produced, determines a board trimming priority in order from a door material with a large number of required numbers, and executes a first board trimming plan. The production plan creation system according to claim 2, wherein the production plan creation system creates the production plan. The first plan making means repeatedly performs the assignment of the original plate and the removal of the door material in the order of the plate removal priority, and the length of the remaining portion of the plate in the plate removal state is equal to the length of all products required for production. When the dimensions of the door material cannot be removed, the order of selection as free stock is determined based on the stock days for the free stock number obtained by subtracting the order reserved stock quantity and the lower limit stock quantity from the current stock quantity, 8. The production plan creation system according to claim 6, wherein a first board removal plan for removing a door material for free stock from a remaining portion of the original sheet is prepared based on the selection order. 9. The production plan creating system according to claim 8, wherein when the free stock days exceed a predetermined reference number of days, plate removal from the remaining portion of the original plate is stopped. 9. The production plan creation system according to claim 8, wherein when the number of said free stocks exceeds a predetermined reference number, plate removal from the remaining portion of said original plate is stopped. The first plan making means repeatedly performs the assignment of the original plate and the removal of the door material in the order of the plate removal priority, and the length of the remaining portion of the plate in the plate removal state is equal to the length of all products required for production. When the size of the door material becomes impossible, a first planing plan is prepared in which the door material of the product of the product number of the free stock object specified in advance is planed from the remaining portion of the original plate. 8. The production plan creation system according to claim 6, wherein: The above-mentioned second plan making means, when performing plate removal from a fixed-size original plate for a door material of a product requiring production, repeats the plate removal of the door material from the original plate in units of product numbers. After the board has been cut for all product numbers that need to be produced, if there are more than a predetermined number of original sheets with the same boarding pattern, door materials for products with the same article number as those of the original board A second planing plan is to perform planing and to plan the remaining parts of the plank with different planing patterns to plan the door material of the product having the same part number as the part number already allocated to the base plate for free stock. The production plan creation system according to any one of claims 2 to 11, wherein the system is created. The above-mentioned second plan making means, when performing plate removal from a fixed-size original plate for door material of a product requiring production, repeats the plate removal of the door material from the original plate for each product part number. If the demand priority of the part number assigned to the original sheet is equal to or greater than the predetermined value after performing the board cutting for the part numbers of all products that require production, the same part number as the part number already assigned to the rest of the original sheet The production plan creation system according to any one of claims 2 to 11, wherein a second board plan is created in which boarding of the door material of the product is performed for free stock. The above-mentioned second plan making means, when performing plate removal from a fixed-size original plate for a door material of a product requiring production, repeats the plate removal of the door material from the original plate in units of product numbers. After performing board cutting for all product numbers that require production, integrate the board plan with the length of the remaining part of the original plate equal to or larger than the specified dimension into the plan with the minimum length of the remaining part of the original sheet. The production plan creation system according to any one of claims 2 to 11, wherein the second plan drawing plan is created by doing so. The above-mentioned second plan making means, when performing plate removal from a fixed-size original plate for a door material of a product requiring production, repeats the plate removal of the door material from the original plate in units of product numbers. After removing all product numbers that require production, the remaining length of the original plate whose length is equal to or greater than the specified size is obtained by subtracting the order reserve inventory and the lower limit inventory from the current inventory. To determine the order of selection as free stock based on the number of days in stock relative to the number of stocks, and to create a second plan to plan door materials for free stock from the remaining part of the original sheet based on the selection order. The production plan creation system according to any one of claims 2 to 11, wherein: A database for storing information on yield, productivity, and the number of days in stock for each color and pattern of door material and door width is provided as an evaluation criterion for the planing plan. Yield, productivity, and the number of days in stock are calculated for each of the color and pattern of the door material and the door width, and the evaluation values for the totaled yield, productivity, and number of days in stock are calculated. 16. The production plan creation system according to claim 2, wherein an evaluation value is compared for each color pattern and width of the door material to determine a finally adopted planing plan. 17. The production plan creation system according to claim 16, wherein a predetermined weighting is performed at the time of calculating the evaluation value and the weight is corrected. 18. The production plan creating system according to claim 2, further comprising a storage medium for storing data of the plan plan finally determined by said plan plan evaluation means.

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