JP2005216198A - Method for adjusting quantity of material to be ordered in material supply - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve a problem that high-accuracy material ordering can not be performed by the occurrence of delivery delay of slave components to a product manufacturer since a slave component manufacturer makes a mistake in reading variations. <P>SOLUTION: Information relating to the quantity of materials in stock that a slave component manufacturer has, is held at a product manufacturer side and when ordering a slave component from the product manufacturer to the slave component manufacturer, the quantity of slave components scheduled to be next ordered calculated by the product manufacturer is described in an order statement and reported to a vender. At the same time, materials required for manufacturing the slave components to be ordered are supplied, and the quantity of supplied materials is held as theoretical stock for each slave component manufacturer. When the ordered slave components are delivered to the product manufacturer, the quantity of required materials is calculated again from the quantity of delivered slave components, and subtracted from the theoretical stock and when next ordering slave components, the quantity of materials required for manufacturing the slave components is first calculated from the slave components to be ordered similarly to the last time. When supplying the required materials, materials are supplied for the quantity subtracting a numerical value of the theoretical stock. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for adjusting a material order quantity for calculating a material amount required by a manufacturer of child parts.

  Conventionally, when a product manufacturer places an order for a child part necessary for the product from the child part manufacturer, the child part manufacturer can use the product manufacturer's purchase order, future order quantity plan, or past order quantity information. Estimate the amount of material required for manufacturing the child parts, adjust the material order quantity so as not to have excessive material inventory, and prevent delays in delivery due to insufficient material inventory, and management of material inventory Adds the stock quantity (stock quantity in the warehouse) when the material is delivered from the material supplier, and when the child part or material is withdrawn from the stock warehouse in the actual product manufacturing process, The inventory quantity in the warehouse of child parts or materials is managed by subtracting the inventory quantity in the warehouse and further taking inventory of the inventory warehouse periodically. There exists patent document 1 as this example.

JP 2001-167218 A

  In the conventional method, since the purchase plan of the material used by the child component manufacturer is entrusted to each child component manufacturer, when the child component manufacturer procures the material, there is sufficient material for the convenience of the material purchase funds. Because the numerical value fluctuates until the order quantity from the product manufacturer changes from the order plan to the firm order, the sub-part manufacturer misreads the change, and the sub-parts to the product manufacturer are neglected. Delivery time may be delayed. In addition, each child component manufacturer may have purchased the same type of material. In this case, the volume of the same type of material for each child component manufacturer is purchased from the material supplier. By discounting, it is possible to reduce the unit price of materials, and it is possible for child component manufacturers to reduce planning and ordering work for material procurement, and as a result, the manufacturing cost of child components can be reduced. The effect can be expected.

  As a means for solving the above-mentioned problem, there is a method (material supply) in which a product manufacturer performs a bulk purchase of the same type of material used by each child component manufacturer and then supplies the same to each child component manufacturer. However, in the conventional material supply, when the product manufacturer places a firm order, the quantity of material required by the child parts of the firm order quantity is calculated, and the product manufacturer calculates and purchases the purchased material based on the product production plan. Either pay to the parts manufacturer for a fee or free of charge, or place an order for the sub-parts and the material supplier, and supply the sub-parts manufacturer for a fee or for free. It is necessary to check the supplier's existing amount of material, increase or decrease the amount of material provided, and adjust the material order amount. To that end, the amount of material delivered from the material supplier to the child component manufacturer, to the product manufacturer Depending on the amount of material consumed by the delivery results of child parts, the amount of material consumed by the yield in the manufacturing process of the child parts manufacturer, and the amount of material when the supplied material is diverted to other product manufacturers Understanding the amount of materials in the warehouse It should be performed in consideration of the variation history over time to. An object of the present invention is to solve the above problems.

  In order to achieve the above object, the present invention has the following configuration. First, when the product manufacturer holds information (theoretical inventory) of the material inventory of the child component manufacturer, the next time the product manufacturer calculates when the child product is ordered from the product manufacturer to the child component manufacturer. At the same time, we will post the planned order quantity of the child parts in the purchase order and communicate it to the vendor as information.At the same time, we will supply the materials necessary for manufacturing the ordered child parts for a fee or free of charge. Each child component manufacturer holds a theoretical inventory, and when the ordered child component is delivered to the product manufacturer, the necessary materials and material quantities are calculated again from the delivered child component quantity, When subtracting, the next time you order a child part, first calculate the amount of material required for manufacturing the child part from the child part you ordered, and subtract the theoretical inventory value when supplying the necessary material. The amount of materials at is provided.

  According to the present invention, it is possible to order a more accurate material.

    Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is an overall view of a system in an embodiment of the present invention, 101 is a manufacturer of a product in this example, 102 is a manufacturer of child parts ordered by the product manufacturer 101, and 103 is a product manufacturer 101. Is a supplier of materials to be ordered and supplied to the child component manufacturer 102, 111 is a process of calculating required parts that the product manufacturer 101 needs to manufacture the product, and 112 is a child to order as a result of 111 A part order, 113 is a material order, 131 is a system for calculating the order of materials to be supplied to each sub-part manufacturer and placing an order, 121 is a sub-part delivered by the sub-part manufacturer 122 indicates the flow of the supplied material.

  2 shows the internal configuration of the material ordering system 131 in FIG. 1, the material ordering system 201 in FIG. 2 is the same as 131 in FIG. 1, and the child part order quantity result 211 is the same as 112 in FIG. The material order form 214 is the same as 113 shown in FIG. 231 in FIG. 2 is a program for updating the material inventory amount of each child component manufacturer, and 232 is a program for calculating a required amount of material necessary for child component manufacturing from the child component order quantity result 211. Is a program for calculating the required amount of the required material, 234 is a program for issuing a material purchase order from the adjustment result of the material order quantity, and 221 is for managing the material inventory quantity of each child component manufacturer A table 222 stores information on each child component and the material and material amount required by the child component so that the material requirement calculation program 232 calculates the material and material amount required for each child component. Show.

  Next, a table used for material inventory management and material requirement management will be described. 3 is the same as the theoretical stock table 221 in FIG. 2, and the pre-processing stock quantity 301 and the production plan 302, the order quantity / order forecast quantity 303, the stock quantity 304, the safety stock quantity 305, and the material supply amount in each arrangement period Pn 310. The number of parts 306 is constituted by the current time axis Tc320. 4 is the same as the material configuration table 222 in FIG. 2, and the part number 401, the part name 402, the parent part name 403, the child part name 404, the number of child parts 405 for the parent part, the material type 406, the inner diameter 407, and the outer diameter. 408, width 409, height 410, length 411, weight 412, quantity 413, unit 414, defect rate 415 are configured.

  FIG. 5 is a flowchart showing the operation of the inventory update program 231 shown in FIG. The operation of the inventory update program 231 in FIG. 5 will be described below with reference to FIG. In step 501, the confirmed order quantity from the child part order quantity result 211 in FIG. 2 is registered in the order quantity / order estimate number 303 in FIG. In the arrangement period Pn, the order quantity from the product manufacturer to the child parts manufacturer is fixed, and the delivery period for the order is Px (x → n substitution). Also, Ty is the time axis Tc at the time of order confirmation and ordering (y → c substitution). Further, if the predicted order quantity to be provided from the product manufacturer to the child component manufacturer together with the ordered quantity varies from the predicted order quantity sent before Ty, the process proceeds from step 502 to step 503 in the same manner, and the predicted order quantity is obtained. Update the number, the number of inventory, and the number of inventory before processing. In step 502, if the Px order quantity at Ty and the predicted number of Px + 1 orders in the previous period Ty-1 do not change, the process proceeds to step 506. If the change occurs, the process proceeds to step 503 and the inventory quantity is updated. Further, the variation of each predicted order number after Px + 1 at Ty and the predicted order number after Px + 2 corresponding to Ty−1 are similarly determined. If there is a variation, the process proceeds to Step 503. In step 503, the number of stocks in the arrangement period Px = the number of pre-processing stocks- (the number of orders / the number of predicted orders-production plan) is calculated, and the number of stocks is updated. In step 504, the inventory quantity at Px becomes the same as the inventory quantity before processing at Px + 1, and the inventory quantity before processing at Px + 1 is updated. Here, the stock quantity before processing is a value before the fluctuation of the inventory quantity due to the production plan fluctuation or the order quantity fluctuation in a certain arrangement period. In step 505, as in steps 503 and 504, the stock quantity and the pre-processing stock quantity are updated for Px + 1 and later. If there is no change in the production plan after Pn in step 506, the process is terminated. If there is a change in the production plan, the production plan is updated in step 507. In step 507, the production plan in Pz is updated. In steps 503 to 506, the number of stocks after Pz and the number of pre-processing stocks are updated. Here, Pz indicates an arrangement period in which the production plan varies after Pn. With this configuration, in order to quickly grasp inventory fluctuations due to fluctuations in the order quantity or forecasted order quantity, it is possible to reduce excess inventory or inventory shortage by updating the inventory quantity in the future and adjusting the number of materials provided. is there. The material supply number adjustment program will be described below.

  FIG. 6 is a flowchart showing the operation of the material supply number adjustment program 232 shown in FIG. The operation of the material supply number adjustment program 232 in FIG. 6 will be described below with reference to FIG. In step 601, a timing period Pm for material supply is determined. Pm, which is the timing of material supply, is an arrangement period in which production lead time is added to Pn. The production lead time varies depending on the individual parts, and the Pm material supply arrangement period is set for each part. In step 602, the difference between the stock quantity and the safety stock quantity is added from the forecast order quantity in Pm, and the material supply part is calculated. Formula: Order forecast quantity-(stock quantity-safety stock quantity) Pm material supply part Update the number of parts. The calculated number of parts for material supply represents the amount of material necessary for producing the part quantity in the arrangement period Pm by the number of parts. This calculation formula is based on the safety stock quantity and is configured to reduce fluctuations in the stock quantity. In step 603, at the first stage Tc + 1, materials corresponding to the material supply part quantity calculated in the Pm period at Tc are supplied from the material supplier to the child part manufacturer, and the production plan for that part number is Tc. Update as production plan for +1 Pm-1 period. That is, in the Tc + 1 inventory table, the number of parts for material supply calculated in step 602 is the same as the numerical value of the Pm-1 production plan. In step 604, based on the production plan updated in step 603, the stock quantity and the pre-process stock quantity are the same as in step 503 in FIG. 5, the stock quantity = the pre-process stock quantity- (order quantity / order estimate quantity-production The Pm-1 inventory quantity is updated by the calculation formula of (plan), and the inventory quantity before Pm processing is also updated in the same manner as in step 504. Similarly to step 505, the inventory quantity after Pm and the inventory quantity before processing are also updated.

  FIG. 7 is a flowchart showing the operation of the material requirement calculation program 233 shown in FIG. Hereinafter, the operation of the material requirement calculation program 233 of FIG. 7 will be described with reference to FIG. In step 701, a child component manufacturer that is a target of material supply is selected. In step 702, the required material quantity for the required number of parts is calculated from the material configuration table of FIG. Based on the part number 401 in FIG. 4, the part name necessary for the part ordered from the product manufacturer to the child part manufacturer can be grasped from the parent part name 403, the child part name 404, and the number of child parts 405 for the parent part. The material type 406 can classify the diameter for the cylindrical part by the inner diameter 407 and the outer diameter 408, and can classify the shape for the coil or sheet part by the width 409, the height 410, and the length 411, and the necessary materials for the part The amount can be determined based on the weight 412 or the quantity 413 and the unit 414, and the necessary material requirement amount in consideration of the defect rate 415 is calculated. For example, if the defect rate is 3%, the material amount for 103% is calculated. In step 703, the necessary material amount for each material type is totaled. The required material requirements calculated for each child component manufacturer are summarized for each material type, and the total amount of required materials for each material type is calculated. Calculate the required amount for each material type and reduce the material purchase cost by purchasing in bulk.

  FIG. 8 is a flowchart showing the operation of the ordering program 234 shown in FIG. Hereinafter, the operation of the ordering program 234 in FIG. 8 will be described. In step 801, a material purchase order for the amount of material necessary for material supply to all selected child component manufacturers is issued. In step 802, the necessary amount of material for the child component manufacturer at each material supply timing is calculated. In step 803, the material supplier 103 is notified.

  Next, an operation example of the material ordering program will be described with reference to FIGS. 9, 10, 11, 12, and 13. FIG. 9 is an example of the inventory table 221 on the time axis Tc. The inventory update program performs the following operations. Since there are 20 pre-processing stocks in Pn, production plan 21 and ordering number 22, one shipment is required from the stock, and 19 is the stock quantity minus 1 from the pre-processing stock. The inventory quantity in Pn is the inventory quantity before processing of Pn + 1, and the inventory quantity of Pn + 1 is 20 based on the production plan, the order quantity, and the estimated order quantity by the same calculation formula. The material supply number adjustment program performs the following operations. If the material supply timing is determined to be Pn + 4, the number of parts for material supply in Pn + 4 is 23 according to the calculation formula of step 602 in FIG. 6, the predicted order quantity 25- (stock quantity 20-safety stock quantity 18). Calculated and updated.

  FIG. 10 is an example of the inventory table 221 on the time axis Tc + 1. The Tn + 1 Pn + 3 production plan is updated from 25 to 23 based on the Pn + 4 material supply part number 23 in Tc calculated in FIG. According to step 506 in FIG. 5, the production plan is changed, and the Pn + 3 inventory quantity and the pre-processing inventory quantity and inventory quantity after Pn + 4 are updated. The number of Pn + 4 material supply parts 25 at Tc + 1 is updated by the material supply number adjustment program.

  FIG. 11 is an example of the inventory table 221 on the time axis Tc + 2. FIG. 11 shows an example in which the Tc + 1 Pn + 2 production plan 22 is updated to the Tc + 2 Pn + 1 production plan 27. As the production plan increases by 5, the stock quantity after Pn + 1 is updated, and the number of parts supplied for Pn + 4 material is 27, which is 5 less than the predicted order quantity 32 to adjust with the safety stock quantity.

  FIG. 12 is an example of the inventory table 221 on the time axis Tc + 3. FIG. 12 is updated from Tc + 2 Pn + 3 production plan 25 to Tc + 3 Pn + 2 production plan 23, and Tc + 2 Pn + 4 Pn + 4 based on the number of Pn + 4 material supply parts 27 In this example, the production plan 32 is updated to a Pn + 3 production plan 27 of Tc + 3. As the Pn + 2 production plan is reduced by 2 and the Pn + 3 production plan is reduced by 5, the stock quantity after Pn + 2 is updated, and the number of parts provided for Pn + 4 material is ordered to adjust with the safety stock quantity. Register 37, which is 2 more than the predicted number 35.

  FIG. 13 is an example of the inventory table 221 on the time axis Tc + 4. FIG. 13 shows an example in which the safety stock number of Pn + 4 is updated to 15 which is 3 less than the Pn + 4 safety stock number 18 of Tc + 3. As the safety stock number of Pn + 4 is updated, 37, which is 3 less than the predicted order number 40, is registered as the number of parts for Pn + 4 material supply to adjust the stock number and the safety stock number.

  According to the present invention, the ordering of materials can be realized using a computer.

Overall view Material ordering system internal configuration diagram Stock table Material composition table Flow chart showing operation of inventory update program Flow chart showing the operation of the material supply number adjustment program Flow chart showing operation of material requirement calculation program Flow chart showing operation of ordering program Update example of inventory table Update example of inventory table Update example of inventory table Update example of inventory table Update example of inventory table

Explanation of symbols

DESCRIPTION OF SYMBOLS 101 Product manufacturer 102 Child component manufacturer 103 Material supplier 131 Material ordering system 231 Inventory update program 232 Material supply number adjustment program 233 Material requirement calculation program 221 Inventory table 222 Material composition table

Claims (1)

In the method of adjusting the amount of material order for controlling the order of the child parts required for product manufacture by the product manufacturer using a computer,
The child component manufacturer's device calculates the necessary amount calculated by taking the material inventory of the child component manufacturer into account for the material required for the order from the material manufacturer,
The product manufacturer's equipment adjusts the quantity of materials required for this order, taking into account the current stock quantity of the child parts manufacturer, and adjusts the stock quantity according to the stock order fluctuations in the future due to fluctuations in the production order. In contrast, materials are provided for a fee or free of charge, and material supply at a timing that takes into account the manufacturing lead time of the child component manufacturer reduces the material purchase work of the child component manufacturer, resulting in the material shortage of the child component manufacturer. Reduce product delivery delays due to manufacturing process delays, and competition for product prices produced by product manufacturers due to reduction of inventory costs and required material costs of child component manufacturers in the supply of materials managed by product manufacturers A method for adjusting a material order quantity in material supply, characterized in that the power can be improved.

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