JP2007047981A - Production plan output program and production plan output device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To respond to a production system such as small lot multi-product production or one-by-one production. <P>SOLUTION: The production plan output device 1 comprises demand data 22 based on a customer's request which is associated with a requested date and a requested quantity for each product item, threshold data 30 associated with an accumulated quantity and the number of collecting days, and a lot collection accelerated number of days calculation means 11 initializing and sorting the accumulated quantities in descending order of the total requested quantity in an object operation period for outputting production plan data 33, and repeating, for all product items in the sorted order, processing for adding a requested quantity of a predetermined item to the accumulated quantity, extracting a number of collection days associated with the added accumulated quantity, and storing the product item concerned and the extracted number of collection days in association with each other as lot collection data 31 in a storage device. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a production plan output program and a production plan output device for outputting production plan data including items and quantities to be produced on a predetermined working day.

  As mass production products in recent years, with the diversification of products, it is possible to maintain the smallest work-in-progress and product inventory, and to meet customer requirements with a short lead time, and one-off production. The production method is ideal. Here, the work-in-process is a product being produced on the production line.

  Examples of mass-produced products include home appliances and OA products. In these products, generally, press, injection molding, printed circuit board mounting, etc. are located in the first half of the production process, and the parts produced in these processes are used in the second half of the assembly process. There are many cases. In these cases, when the member requirement is calculated by MRP (material requirements planning), the number of parts is also a required quantity. On the other hand, the process related to setup man-hours is often a part manufacturing process, and when a request for one unit comes, the production is performed in consideration of production efficiency. For this reason, the MRP and the production scheduler set production lots for these parts, and create a collective production instruction and a collective production plan at the part requirement and part production planning stage.

  In this way, in production processes that require setup changes such as press, injection molding, and pudding board mounting, production lot quantities are generally set and production is performed for each production lot quantity in order to improve production efficiency. ing.

As a method for calculating the production lot quantity, an economic lot size method (EOQ method) is known (see Non-Patent Document 1). When the production lot quantity is calculated for an item whose demand is stabilized to some extent by the economic lot size method, it is assumed that the dispensed quantity, production quantity, and cost are expressed as follows.
Payout amount per unit period: r (pieces / unit period)
Production volume per unit: m (pieces / unit period)
Storage cost for unit period: C _i (yen / (unit / unit period))
One setup fee: C _s (yen / time)
Production period: t1 (period) = Q / m
1 cycle period: t2 (period) = Q / r
Lot size: Q (pieces)
In this case, the economic lot size Q ^* is expressed by Equation 1.

Q ^* = (2 mC _s r / C _i (m−r)) ^1/2 (Expression 1)

  When a production plan is drawn up based on the economic lot size calculated by the above-described equation 1, it is possible to set a lot size that minimizes the total cost that balances production efficiency and member management costs.

  A production plan output apparatus 900 using such a conventional production lot quantity calculation method has a configuration as shown in FIG. Specifically, in the conventional production plan output device 900, data used in the production plan output device 900 is input from the backbone system 950 and stored in the storage device 907a. The storage device 907a includes item master data 911, demand data 912, WIP (work in process) data 913, manufacturing process data 914, device capability data 915, BOM (bill of materials) data 916, work day calendar data 917, parts Data necessary for production planning, such as inventory data 918, personnel plan data 919, lot summary data 920, and advance days data 921, is stored. Furthermore, the data stored in the storage device 907a is read out by the scheduler means 931 implemented by executing the program in the central processing control device 901, and the production plan data 922 is output and stored in the storage device 907b. Is done. The core system 950 may be a data input terminal that is input by a person in charge of production planning or a person in charge of a department that manages master data such as item information and process information at a corresponding base.

  Here, the output production plan data 922 includes an example of a data structure and data as shown in FIG. In the production plan data 922, items of products to be produced, quantities to be produced, start date / time, completion date / time, and use device are associated and stored. Specifically, in the production plan data 922, 10 items “A” of the product to be produced are started at “9/17 10:00” and completed at “9/17 12:00”. / J-1 "device is used and contains data indicating that it will be produced.

  In addition, as shown in FIG. 17, the lot summary data 920 includes summary types such as a summary period method and a summary quantity method, a lot quantity to be summarized in the summary period method, and a target to be summarized in the summary quantity method. A summary period is stored in association with each other. The lot quantity is, for example, the economic lot size calculated by the above-described formula 1. Further, the advance days data 921 stores the advance days for each item as shown in FIG.

  Here, the lot summary will be described in detail. As described above, in multi-product small-quantity production, a production plan is made based on customer demand. For example, a case will be described in which the demand quantity on each request date that is a production plan target for the items A to J is as shown in FIG. FIG. 19 shows an example in which a total of 100 items A to J are produced in 20 days as a production plan target. Specifically, on the request date “1”, four items A and one item E are generated. When an item is produced according to this demand, a setup for producing item A and a setup for producing item E occur in order to produce five products. Will occur twice. On the other hand, for item A, demands such as 4 on request date “1”, 7 on request date “2”, 2 on request date “3”, etc. are generated. When the item is produced according to this demand, the item A is produced in 18 days out of the 20 working days to be produced. As shown in FIG. 19, when an item is produced according to demand, a total of 48 setup changes will occur.

For the example shown in FIG. 19, FIG. 20 shows the items and production quantities for each working day when the number of production lots is five. The demand quantity of the item A is 4 for the request date “1”, 7 for the request date “2”, and 2 for the request date “3”. Are 5 working days “1”, 10 working days “2”, and 0 working days “3”. In this case, the total number of setup changes is 24. In this way, by summarizing the production lots, the total changeover on the working day that is the target of the production plan is significantly reduced.
Encyclopedia of production management (Asakura Publishing 1999)

  However, the method for calculating the economic lot size described in Non-Patent Document 1 is based on the premise of an item whose demand is stable to some extent, and is operated with an optimal economic lot size in an environment where demand fluctuations in recent years are large. However, there is a problem that proper production management cannot be performed.

  Along with this, it is required to establish a production summarization method such as calculation of a lot size that can easily cope with a production method such as high-mix low-volume production or single-piece production.

  Accordingly, an object of the present invention is to provide a production plan output program and a production plan output device by a production summarizing method that can easily cope with a production method such as high-mix low-volume production or single piece production.

  A first feature of the present invention is a production plan including items and quantities to be produced on a predetermined working day, which is executed in a computer that processes information stored in a register and a storage device when information is input from an input device. The present invention relates to a production plan output program for outputting data. That is, the production plan output program according to the first feature of the present invention relates to demand data storage means for storing demand data associated with a requested date and a requested quantity for each item in a storage device, and an accumulated quantity and a total number of days. Threshold data storage means for storing the accumulated quantity threshold data in the storage device, and requesting all items in the target operation period for initializing the accumulated quantity, reading the demand data from the storage device, and outputting the production plan data Calculate the total quantity and sort in descending order of the requested quantity for each item in the target operating period, add the requested quantity of the specified item to the accumulated quantity for all items in the sorted order, and accumulate from the storage device The ratio of cumulative quantity added to the total required quantity of all the items calculated by reading the quantity threshold data Extracts the associated summary days, associates the identifier of the item with the extracted summary days and stores it in the storage device as lot summary data, repeats the process of calculating the lot summary advance date, and reads the lot summary data from the storage device Then, the computer executes scheduler means for outputting production plan data.

  According to the production plan output program according to the first feature of the present invention as described above, the larger the production quantity, the fewer the number of days to be summarized. Specifically, production is performed every time demand occurs to reduce the inventory holding cost. At the same time, the smaller the production quantity, the greater the number of days to be summarized, and more specifically, it can be produced in anticipation of a plurality of demands to reduce the cost required for the change of manufacturing setup.

  A second feature of the present invention is a production plan including items and quantities to be produced on a predetermined working day, which is executed in a computer that processes information stored in a register and a storage device when information is input from an input device. The present invention relates to a production plan output program for outputting data. That is, the production plan output program according to the second feature of the present invention relates to demand data storage means for storing demand data associated with the requested date and the requested quantity for each item in the storage device, and the accumulated frequency and the number of days ahead. Threshold data storage means for storing the accumulated frequency threshold data in the storage device, and a request for all items in the target operation period for initializing the accumulated frequency and reading the demand data from the storage device and outputting the production plan data Calculate the sum of the frequencies and sort them in order of increasing request frequency for each item in the target operating period. For all items in the sorted order, add the request frequency of the specified item to the accumulated quantity and accumulate from the storage device. Read the frequency threshold data, and calculate the ratio of the cumulative frequency added to the total required frequency of all items calculated. The number of days in advance is extracted, and the identifier of the item and the extracted number of days in advance are associated with each other and the process of storing the data in the storage device as the number of days in advance is repeated. Then, the computer executes scheduler means for outputting production plan data.

  According to the production plan output program according to the second feature of the present invention, since the inventory risk is lower for items with a higher request frequency, the number of days ahead can be increased and the efficiency of the equipment operation rate can be increased. In addition, because inventory risk is higher for items with lower request frequency, production plan data that reduces the number of setup changes without increasing inventory by shortening the number of days ahead, preventing immovable inventory and preventing deterioration of cash. Can be output.

  A third feature of the present invention is a production plan including items and quantities to be produced on a predetermined working day, which is executed in a computer that processes information stored in a register and a storage device when information is input from an input device. The present invention relates to a production plan output program for outputting data. In other words, the production plan output program according to the third feature of the present invention relates to demand data storage means for storing demand data associated with the requested date and the requested quantity for each item in the storage device, and the accumulated quantity and the total number of days. Threshold data storage means for storing the accumulated quantity threshold data and the accumulated frequency threshold data in which the accumulated frequency and the number of days in advance are associated with each other, and initializing the accumulated quantity, and reading the demand data from the storage device , Calculate the sum of the requested quantity of all items in the target operating period to output production plan data, sort in order of the requested quantity for each item in the target operating period, and for all items in the sorted order, Add the requested quantity for a given item to the cumulative quantity, read the cumulative quantity threshold data from the storage device, and The number of summary days associated with the ratio of the cumulative quantity added to the total requested quantity of the item is extracted, and the process of storing the identifier of the item and the extracted summary days in association with each other in the storage device is repeated. In addition, the cumulative frequency is initialized, the demand data is read from the storage device, and the sum of the request frequencies of all items in the target operation period for outputting the production plan data is calculated. Sort all items in the order of request frequency, add the request frequency of the specified item to the cumulative quantity for all items in the sorted order, read the cumulative frequency threshold data from the storage device, and calculate the request for all items calculated Extract the advance days associated with the percentage of the cumulative frequency added to the total frequency and identify the item. Lot summary advance days calculation means that repeats the process of storing in the storage device as advance date data in association with the extracted advance days, and reads the lot summary data and advance day data from the storage device, and outputs production plan data The scheduler means for executing is executed by the computer.

  Here, the threshold data storage means further stores correction threshold data associated with a new advance date based on the accumulated quantity and the accumulated frequency in the storage device, and lot summary data, advance date data, and correction threshold data from the storage device. Is read out, and the new advance days based on the accumulated quantity and the accumulated frequency are extracted as corrected advance days, and the identifier of the item and the corrected advance days are associated with each other and stored as corrected advance days data. It is preferable to further include a forward days correction unit that repeats the process of storing the information. In this case, the scheduler means reads the lot summary data and the correction advance date data from the storage device, and outputs the production plan data.

  According to the production plan output program according to the third feature of the present invention, the production plan data can be output by correcting the number of days ahead based on the correlation between the demand quantity requested and the demand frequency.

  According to a fourth aspect of the present invention, when information is input from an input device, a production plan is executed in a computer that processes the information while storing the information in a register and a storage device. The present invention relates to a production plan output device that outputs data. In other words, the production plan output device according to the fourth feature of the present invention is a demand data storage means for storing demand data associated with a requested date and a requested quantity for each item in a storage device, and an accumulated quantity and a total number of days are associated with each other. Threshold data storage means for storing the accumulated quantity threshold data, the accumulated frequency and the accumulated frequency threshold data associated with the advance number of days in the storage device, and initializing the accumulated quantity, and reading the demand data from the storage device, Calculate the total required quantity of all items in the target operating period for which production plan data is output, sort in descending order of the required quantity for each item in the target operating period, and specify all items in the sorted order. Add the requested quantity of the item to the cumulative quantity, read the cumulative quantity threshold data from the storage device, and calculate all the calculated items. Extract the summary days associated with the ratio of the cumulative quantity added to the total of the requested quantity, repeat the process of associating the identifier of the item with the extracted summary days and storing it in the storage device as lot summary data, and accumulate In addition to initializing the frequency, the demand data is read from the storage device, and the sum of the request frequencies of all items in the target operation period for outputting the production plan data is calculated, and the request frequency for each item in the target operation period is calculated. Sort all items in the sorted order, add the requested frequency of the specified item to the cumulative quantity for all items in the sorted order, read the cumulative frequency threshold data from the storage device, and calculate the total required frequency for all items Extract the number of advance days associated with the percentage of the cumulative frequency added to Lot summary advance days calculation means for repeating the process of storing the advance days in association with the advance days data, and scheduler means for reading the lot summary data and advance days data from the storage device and outputting production plan data Is provided.

  According to the present invention, it is possible to provide a production plan output program and a production plan output device by a production summarizing method that can easily cope with a production method such as high-mix low-volume production or single piece production.

  Next, embodiments of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals.

(Best Embodiment)
The production plan output device 1 according to the preferred embodiment of the present invention, when information is input from the input device, processes while storing the information in the register and the storage device, and the items and quantities to be produced on a predetermined working day As shown in FIG. 1, the apparatus includes a central processing control device 101 and storage devices 107a, 107b, and 107c. Data referred to by the production plan output device 1 according to the best embodiment of the present invention is input from the backbone system 2 that holds various data of the production factory. Further, data referred to in the production plan output device 1 may be input from the data input terminal by a person in charge of production planning or a person in charge of a department that manages master data such as item information and process information at the corresponding base.

  As shown in FIG. 2, the production plan output device 1 according to the preferred embodiment of the present invention includes a central processing control device 101, a ROM (Read Only Memory) 102, a RAM (Random Access Memory) 103, and an input / output interface 109. Are connected via the bus 110. An input device 104, a display device 105, a communication control device 106, a storage device 107, and a removable disk 108 are connected to the input / output interface 109.

  The central processing control device 101 reads and executes a boot program for starting the production plan output device 1 from the ROM 102 based on an input signal from the input device 104, and further reads an operating system stored in the storage device 107. Further, the central processing control device 101 controls various devices based on input signals from the input device 104, the communication control device 106, etc., and reads programs and data stored in the RAM 103, the storage device 107, etc. into the RAM 103. A processing device that loads and implements a series of processes to be described later, such as data calculation or processing, based on a program command read from the RAM 103.

  The input device 104 includes input devices such as a keyboard and a mouse through which an operator inputs various operations. The input device 104 generates an input signal based on the operation of the operator, and inputs via the input / output interface 109 and the bus 110. It is transmitted to the central processing control apparatus 101. The display device 105 is a CRT (Cathode Ray Tube) display, a liquid crystal display, or the like. The display device 105 receives an output signal to be displayed on the display device 105 from the central processing control device 101 via the bus 110 and the input / output interface 109. It is a device that displays the processing result of the control device 101 and the like. The communication control device 106 is a device such as a LAN card or a modem, and is a device that connects the production plan output device 1 to a communication network such as the Internet or a LAN. Data transmitted / received to / from the communication network via the communication control device 106 is transmitted / received to / from the central processing control device 101 via the input / output interface and bus 110 as an input signal or an output signal.

  The storage device 107 is a semiconductor storage device or a magnetic disk device, and stores programs and data executed by the central processing control device 101. The removable disk 108 is an optical disk or a flexible disk, and signals read / written by the disk drive are transmitted / received to / from the central processing control apparatus 101 via the input / output interface 109 and the bus 110.

  The storage device 107 of the production plan output device 1 according to the preferred embodiment of the present invention stores a production plan output program, as well as item master data 21, demand data 22, WIP data 23, manufacturing process data 24, Device capability data 25, BOM data 26, working day calendar data 27, parts inventory data 28, personnel plan data 29, threshold data 30, lot summary data 31, advance date data 32, and production plan data 33 are stored. Further, the production plan output program is read into the central processing control device 101 of the production plan output device 1 and executed in cooperation with the operation system, whereby the lot summary advance days calculating means 11 and the scheduler means 12 are changed to the production plan output device. 1 is implemented.

  In FIG. 1, data is stored in each of the storage devices 107a, 107b, and 107c. However, these data may be physically stored in a plurality of storage devices or stored in a single storage device. good. Further, the production plan output device 1 according to the best embodiment of the present invention may be mounted on one hardware computer or may be mounted on a plurality of hardware computers. Specifically, each data stored in each of the storage devices 107a, 107b, and 107c in FIG. 1 may be stored in a storage device mounted on a different computer capable of transmitting and receiving data via the communication control device 106 and the like. good.

  The item master data 21 stores information on product items or parts items managed by the production plan output device 1 according to the preferred embodiment of the present invention. Specifically, the item master data 21 includes product item identifiers, delivery lead times, delivery units, etc. as product item information, and part item identifiers, purchase lead times, purchase units, etc., as part item information. Is remembered. Further, other data stored in the storage device 107a may include information such as delivery lead time and purchase lead time.

  The demand data 22 is data based on a request from a customer, and a request date and a requested quantity for each item are associated with each other. In the example shown in FIG. 19, specifically, on the request date “1”, four items A and one item E are generated.

  The WIP data 23 is data of work-in-progress that has started to manufacture products but has not been completed. The WIP data includes, for example, information such as work-in-progress item, quantity, completed manufacturing process, and inventory location.

  The manufacturing process data 24 stores information in which the identifier of the product item stored in the item master data 21 is associated with the identifier of the manufacturing process for manufacturing the product item. Furthermore, the information regarding the process capability in the manufacturing process may be related. In order to manufacture a certain product item, for example, passing through a drilling process, a polishing process, and a packaging process is stored in the manufacturing process data 24. The manufacturing process data 24 may be associated with manufacturing apparatuses used in the respective manufacturing processes, process capabilities of the manufacturing apparatuses, and the like.

  The device capability data 25 is data in which a manufacturable quantity per unit time is associated with a device used in the manufacturing process.

  The BOM data 26 is data relating to a part configuration in which a part item constituting a product item is associated with its quantity.

  The working day calendar data 27 is information in which the working day of the production line managed by the production plan output device 1 according to the preferred embodiment of the present invention is stored. The working day calendar data 27 is information in which the working day of the manufacturing process is associated with the identifier of the process information. For example, the working day calendar data 27 is associated with a flag indicating the working day and non-working day of the production line on a general calendar day. This operating day may be set for each manufacturing process or manufacturing apparatus, and may further be associated with the operating time of the manufacturing process or manufacturing apparatus.

  The parts inventory data 28 stores data related to parts items delivered from parts suppliers and the like and stocked in warehouses. For example, the part inventory data 28 is associated with an identifier of a part item, an identifier of an inventory warehouse, an inventory quantity, and the like.

  The personnel plan data 29 is data on shifts of workers required for manufacturing products. In the personnel plan data 29, for example, the number of workers is associated with each working day.

The threshold data 30 includes cumulative quantity threshold data 30a and cumulative frequency threshold data 30b.
The accumulated quantity threshold value data 30a is associated with the accumulated quantity and the number of days. Specifically, in FIG. 3, the cumulative quantity threshold value data 30a associates the ratio of the cumulative quantity with respect to the sum of the requested quantities of all items in the target operating period, and the number of days to be summarized for lot grouping. The “cumulative quantity” is a variable that is processed by the lot summary advance day calculation unit 11 described later, and is calculated for each item. Specifically, the accumulated quantity is a quantity obtained by sorting the total requested quantity for each item in the target operation period in which production plan data is output for the demand data 22 in descending order. The “accumulated quantity ratio” is a variable that is processed by the lot summary advance days calculation unit 11 described later, and is the ratio of the accumulated quantity to the total requested quantity of all items in the target operating period for outputting production plan data. . In the example shown in FIG. 3, when the ratio of the cumulative quantity as “gr1” is less than 70%, the total number of days associated with the cumulative quantity is “1 day”, and the ratio of the cumulative quantity as “gr2” is 70%. When the percentage is less than 80%, the total number of days for the item is “2 weeks” and “gr3”, and when the proportion of the cumulative quantity is 80% or more and 100% or less, the number of days for the item is “4 weeks” Yes. In this way, in the accumulated quantity threshold data 30a, the accumulated quantity and the number of days are associated with each other so that the number of days to be collected becomes smaller as the requested quantity in the target operation period increases.

  Also, the cumulative frequency and the number of days ahead are associated with the cumulative frequency threshold data 30b shown in FIG. Specifically, in FIG. 4, the cumulative frequency threshold data 30 b is associated with the ratio of the cumulative frequency to the total of the request frequencies of all items in the target operating period, and the number of days ahead of production. The “cumulative frequency” is a variable that is processed by the lot summary advance day calculation unit 11 described later, and is calculated for each item. Specifically, the cumulative frequency is a quantity obtained by sorting the request frequencies for each item in the target operation period in which production plan data is output for the demand data 22 in descending order. The “accumulated frequency ratio” is a variable that is processed by the lot summary advance days calculation unit 11 described later, and is a ratio of the accumulated quantity to the total of the requested frequencies of all items in the target operation period for outputting the production plan data. . In the example shown in FIG. 4, when the rate of cumulative frequency is less than 70% as “gr1”, the rate of cumulative frequency is “2 weeks” and “gr2” is the number of days ahead of the item associated with the cumulative frequency rate. If it is 70% or more and less than 80%, if the cumulative frequency ratio is 80% or more and 100% or less as “1 week” or “gr3”, the item's summary days “0 days” are associated with each other. It has been. In this way, in the threshold data 30b, the higher the cumulative frequency ratio, more specifically, the more the number of production days in the target operating period, the higher the cumulative frequency ratio and the forward days so that the forward days are longer. ing.

  In the case of outputting the number of days to be summarized based on the accumulated quantity, the lot summary advance days calculation means 11 initializes the accumulated quantity as a variable, reads the demand data 22 from the storage device 107, and outputs the production plan data 33. The total required quantity of all items in the target operating period is calculated and sorted in descending order of the required quantity for each item in the target operating period. Further, the lot collection advance days calculation means 11 adds the requested quantity of the predetermined item to the accumulated quantity for all the items in the sorted order, reads the accumulated quantity threshold data 30a of the threshold data 30 from the storage device 107, and calculates it. The total number of days associated with the ratio of the added cumulative quantity to the sum of the requested quantity of all the items that have been added is extracted. Further, the lot summary advance date calculation means 11 associates the identifier of the item with the extracted summary days and stores it in the storage device 107 as the lot summary data 31. The lot summary advance days calculation means 11 repeats the process of extracting the summary days for all items and outputting them to the lot summary data 31.

  In addition, when the lot summary advance days calculation means 11 outputs the advance days based on the requested frequency, the lot accumulation advance days initialization unit initializes the cumulative frequency as a variable, reads the demand data 22 from the storage device 107, and generates the production plan data 33. The sum of the request frequencies of all items in the target operation period to be output is calculated and sorted in descending order of the request frequency for each item in the target operation period. Furthermore, the lot summary advance days calculation means 11 adds the request frequency of the predetermined item to the cumulative frequency for all the items in the sorted order, reads the cumulative frequency threshold data 30b of the threshold data 30 from the storage device 107, and calculates it. The number of advance days associated with the ratio of the accumulated cumulative frequency to the sum of the required frequency of all items that have been added is extracted. Further, the lot summary advance days calculation means 11 associates the identifier of the item with the extracted advance days and stores it in the storage device 107 as advance days data 32. The lot summary advance days calculation means 11 repeats the process of calculating the advance days for all items and outputting them to the advance days data 32.

  With reference to FIG. 7, the process of outputting the summary date data 31 in the lot summary advance days calculation means 11 according to the preferred embodiment of the present invention will be described. Here, a case will be described in which demand quantities of items A to J on request dates 1 to 20 occur as shown in FIG. As shown in FIG. 19, the storage device 107a according to the preferred embodiment of the present invention includes “4” items for “item A” and “1” items for “item E” on the request date “1”. The occurrence of a demand is stored as demand data 22.

  First, in step S101, the demand data 22 is read from the storage device 107a, and the request date and the requested quantity for each item are calculated. Here, the calculated requested quantity is a quantity when a product is produced every time a demand occurs. In the example shown in FIG. 19, demands for “item A” are 4 on the request date “1”, 7 on the request date “2”, and so on. The total required quantity is calculated as “68”. The request date and the requested quantity for each item calculated by the central processing control apparatus 101 in step S101 are stored in the RAM 103, the storage device 107, etc. of the production plan output apparatus 1.

  On the other hand, in step S102, the total required quantity of all items during the target request date is calculated. In the example illustrated in FIG. 19, the total required quantity of “item A” to “item J” is calculated as “100” and stored in the RAM 103 of the production plan output device 1, the storage device 107, and the like.

  In step S103, the records are sorted in descending order of the requested quantity for each item on the target request date. Specifically, in step S101, the requested quantity of “item A” is calculated as “68”, the requested quantity of “item B” is “11”, the requested quantity of “item C” is “6”, and so on. Record of demand quantity for each request date with “item A” as a key, record of demand quantity for each request date with “item B” as a key, record of demand quantity for each request date with “item C” as a key. Sorted. The records sorted by the central processing control device 101 in step S103 are stored in the RAM 103 of the production plan output device 1, the storage device 107, and the like. Furthermore, in step S104, the accumulated quantity as a variable is initialized. Specifically, the central processing control apparatus 101 stores “0” as the accumulated quantity in the RAM 103, the storage device 107, and the like.

  Next, the process of step S105 is repeated for all items in the order sorted in step S103. In step S105, the requested quantity of the item is added to the accumulated quantity.

  Furthermore, the processing from step S106 to step S108 is repeated for all items in the order sorted in step S103. In step S106, the ratio of the cumulative quantity to the total required quantity in the target period is calculated based on the total of the cumulative quantity calculated in step S105 and the required quantity calculated in step S102. Further, in step S107, the cumulative quantity threshold value data 30a is read from the storage device 107, and the summary days are output based on the ratio of the cumulative quantity calculated in step S106. The summary days output by the central processing control device 101 in step S107 are stored in the storage device 107 by inserting a record associated with the identifier of the item into the lot summary data 31 in step S108.

  Specifically, in the order sorted in step S103, first, the central processing control apparatus 101 executes the processing from step S105 to step S108 for the record of “item A”. Here, for “item A”, the requested quantity calculated in step S101 is “68”. In this case, in step S105, the requested quantity of “item A” calculated in step S101 is added to the accumulated quantity initialized in step S104, and “68” is output as the accumulated quantity. Further, since the total requested quantity on the target request date calculated in step S102 is “100”, the ratio of the cumulative quantity to “item A” is calculated as 68/100 = “68”% in step S106. Further, in step S107, the cumulative quantity threshold value data 30a shown in FIG. 3 is read, and the summary days “1 day” corresponding to the cumulative quantity ratio “68%” is extracted. Further, in step S 108, as shown in FIG. 5, a record in which the item identifier “item A” and the number of days of summary are associated with each other is inserted into the lot summary data 31 and stored in the storage device 107.

  As described above, by executing the processing from step S105 to step S108 for all items, the lot summary data 31 in which the items and the summary periods as shown in FIG. .

  Next, with reference to FIG. 8, a description will be given of the process of outputting the advance date data 32 in the lot summary advance date calculation means 11 according to the preferred embodiment of the present invention. Here, a case will be described in which the number of demands for items A to J on request dates 1 to 20 occurs as shown in FIG.

  First, in step S151, the demand data 22 is read from the storage device 107a, and the number of production days for each item is calculated as the request frequency. Here, the calculated request frequency is a quantity when a product is produced every time demand occurs. In the example illustrated in FIG. 19, for “item A”, request dates “1”, “2”, “3”, “4”, “6”, among the 20 days of request dates “1” to “20”, “7”, “8”, “9”, “11”, “12”, “13”, “14”, “15”, “16”, “17”, “18”, “19”, “20 ”In 18 days in total, the request frequency of“ item A ”is calculated as“ 18 ”. The request frequency for each item calculated by the central processing control device 101 in step S151 is stored in the RAM 103 of the production plan output device 1, the storage device 107, and the like.

  On the other hand, in step S152, the sum of the request frequencies of all items during the target request date is calculated. In the example illustrated in FIG. 19, the total request frequency of “item A” to “item J” is calculated as “48” and stored in the RAM 103 of the production plan output device 1, the storage device 107, and the like.

  In step S153, the records are sorted in descending order of request frequency for each item on the target request date. Specifically, in step S151, “item A” with request frequency “18”, “item B” with request frequency “10”, “item C” with request frequency “6”, and so on are sorted. The request frequency calculated by the central processing control device 101 in step S153 is stored in the RAM 103, the storage device 107, etc. of the production plan output device 1. In step S154, the variable cumulative frequency is initialized. Specifically, the central processing control device 101 stores “0” as the cumulative frequency in the RAM 103, the storage device 107, and the like.

  Next, the processing of step S155 is repeated for all items in the order sorted in step S153. In step S155, the request frequency of the item is added to the cumulative frequency.

  Further, the processing from step S156 to step S158 is repeated for all items in the order sorted in step S153. In step S156, the ratio of the cumulative frequency to the total request frequency in the target period is calculated based on the total of the cumulative frequency calculated in step S155 and the request frequency calculated in step S102. In step S157, the cumulative frequency threshold value data 30a is read from the storage device 107, and the number of days ahead is output based on the cumulative frequency ratio calculated in step S156. The advance date output by the central processing control apparatus 101 in step S157 is stored in the storage device 107 by inserting the record associated with the identifier of the item into the advance date data 32 in step S158.

  Specifically, in the order sorted in step S153, first, the processing from step S105 to step S108 is executed by the central processing control apparatus 101 for “item A”. Here, for “item A”, the request frequency calculated in step S101 is “18”. In this case, in step S155, the request frequency of “item A” calculated in step S151 is added to the accumulated quantity initialized in step S154, and “18” is output as the accumulated quantity. Further, since the sum of the request frequencies on the target request date calculated in step S152 is “48”, the ratio of the cumulative quantity to “item A” is calculated as 18/48 = “37.5”% in step S156. Is done. Further, in step S157, the cumulative frequency threshold value data 30b shown in FIG. 4 is read, and the number of advance days “2 weeks” corresponding to the cumulative frequency ratio “37.5%” is extracted. Further, in step S158, as shown in FIG. 6, a record in which the item identifier “item A” and the advance date “2 weeks” are associated with each other is inserted into the advance date data 32 and stored in the storage device 107.

  As described above, by executing the processing from step S155 to step S158 for all the items, the items as shown in FIG. 6 and the advance date data 32 in which the advance days are associated with each other are stored in the storage device 107. The

  In the example shown in FIG. 19, the production plan data 33 output by the scheduler unit 12 based on the lot grouping advance period and the number of days ahead calculated by the lot group advance day calculation unit 11 according to the preferred embodiment of the present invention. Is shown in FIG. The production quantities for each item and working day shown in FIG. 9 are calculated based on the lot summarization period and the number of days in advance stored in the storage device 107.

  Specifically, “item A” is produced every time demand occurs because the lot summary period is one day and the number of days is two weeks ahead. Specifically, the production quantity for each working day of the item A shown in FIG. 9 is the same as the demand quantity for each request date of the item A shown in FIG.

  On the other hand, as shown in FIG. 19, for example, “item C” has “1” demand for each of the request dates “2”, “9”, “13”, “14”, “16”, and “18”. It has occurred. Further, the lot summarizing period for “item C” stored in the storage device 107 is 4 weeks, and the number of days ahead is “1 week”. Accordingly, a total of six demands generated on the request dates “2”, “9”, “13”, “14”, “16”, “18” are grouped into the operation date “2” as shown in FIG. Production plan data 33 to be produced is output by the scheduler means 12.

  Further, FIG. 10 shows the relationship between the requested quantity and the cumulative quantity ratio for each item that becomes a Pareto analysis book based on the production plan output apparatus 1 according to the preferred embodiment of the present invention. Based on the accumulated quantity with reference to the accumulated quantity threshold data 30a, the item A belongs to “gr1” because the accumulated quantity is “68” for the summary days, and the item B belongs to “gr1” because the accumulated quantity is “79”. And the accumulated quantities of items C through J are “85”, “89”, “93”, “95”, “97”, “98”, “99”, and “100”, respectively. Belongs to. FIG. 11 shows the request frequency and cumulative frequency for each item. Based on the cumulative frequency with reference to the cumulative quantity threshold data 30b, the cumulative frequencies of the item A and the item B are 18/48 = “37.5%” and 28/48 = “58.3%”, respectively, for the advance period. Since it exists, it belongs to “gr1”. Similarly, item C and item D are set to “gr2” because the accumulated frequencies are “70.8%” and “79.2%”, respectively. Items E to J have cumulative frequencies of “87.5%”, “89.6%”, “93.8%”, “95.8%”, “97.9%”, and “100%”, respectively. Since it exists, it belongs to “gr3”.

  As described above, the production plan output device 1 according to the preferred embodiment of the present invention calculates the lot summarization period and the number of days ahead by referring to the threshold data 30 for the demand for each item and the occurrence frequency of the demand. Production plan data is output based on the lot summarization period and the number of days ahead. As a result, the number of setup changes can be reduced, and the inventory can be reduced as much as possible, compared to the case where production is performed each time demand occurs.

  Specifically, conventionally, as shown in FIG. 19, when production is performed every time demand is generated, the setup change requires 48 times. In the best embodiment of the present invention, as shown in FIG. The number of setup changes requires 29 times. Therefore, the production plan output device 1 according to the preferred embodiment of the present invention can reduce the number of times of setup as compared with the case where production is performed every time demand occurs. Conventionally, as shown in FIG. 20, when producing based on a predetermined lot quantity or a lot grouping period and advance days, 130 pieces are produced despite the demand quantity being 100 pieces. In other words, the production plan output device according to the best embodiment of the present invention produces only 100 pieces as in the demand quantity.

  As described above, the production plan output device 1 according to the best embodiment of the present invention can reduce the number of times of setup and suppress the inventory quantity. Accordingly, the work efficiency is improved and the inventory cost is reduced, so that the production cost can be kept low.

  In the production plan output apparatus 1 according to the preferred embodiment of the present invention, the case where the lot summary data and the advance date data are calculated and the production plan data is output has been described. One of them may be calculated and production plan data may be output. In this case, a predetermined numerical value is set as a fixed value for the lot summary data or the advance date data that has not been calculated by the production plan output device according to the preferred embodiment of the present invention, and the production plan data is output.

(Modification of the best embodiment)
As shown in FIG. 12, the production plan output apparatus 1 according to the modification of the best embodiment of the present invention is different in that the production plan output device 1 includes the advance date correction means 13 and the corrected advance date data 34. Furthermore, the modification of the best embodiment of the present invention is different in that the threshold data 30 includes correction threshold data 30c shown in FIG.

  The corrected threshold data 30c is data in which a new advance date is associated with the accumulated quantity and the accumulated frequency. For example, an example of a data structure and data as shown in FIG. 13 is provided. In the example shown in FIG. 13, although described based on the group names of the cumulative quantity threshold data 30a and the cumulative frequency threshold data 30b defined in FIGS. 3 and 4, they are stored as real numbers of the cumulative quantity and cumulative frequency. Also good.

  At this time, the advance days correction means 13 reads the lot summary data 31, the advance days data 32, and the correction threshold data 30c from the storage device 107, and the new advance days based on the accumulated quantity and the accumulated frequency are corrected for all items. The process of extracting the number of advance days and inserting the record that associates the identifier of the item with the corrected advance number of days into the corrected advance number of days data 34 and storing it in the storage device 107 is repeated. Specifically, when the cumulative quantity ratio is “68%” and the cumulative frequency ratio is “87.5%”, the advance date correction means 13 is based on the cumulative quantity ratio according to FIG. 3 and FIG. Since the group is “gr1” and the group based on the cumulative frequency ratio is “gr3”, the corrected group of the number of advance days is “gr2”. Therefore, the corrected number of advance days is calculated as “one week” from the cumulative frequency threshold value data 30b of FIG.

  Next, referring to FIG. 14, the processing of the forward days correction means 13 according to a modification of the preferred embodiment of the present invention will be described. First, for a predetermined item, the lot summarization data 31 is read from the storage device 107 in step S201 to extract the summarization days of the item, and the advance date data 32 is read from the storage device 107 in step S202. The number of days ahead is extracted. Further, in step S203, based on the data read in step S201 and step S202, the correction threshold data 30c shown in FIG. Next, in step S204, a record in which the identifier of the item is associated with the corrected advance date output in step S203 is inserted into the corrected advance date data 34 and stored in the storage device 107. In the advance date correction means 13, the processing from step S201 to step S204 is repeated for all items.

  As described above, according to the production plan output device 1 according to the modified example of the best embodiment of the present invention, the advance days calculated in advance can be corrected in consideration of the correlation between the cumulative quantity and the cumulative frequency. it can.

  In particular, for items that are large in quantity and infrequent, if the number of days in advance is determined based on the frequency alone, it will hardly be moved forward, and production will vary greatly when demand actually occurs. It becomes a plan.

  Therefore, even if the frequency is low, by correcting the number of days ahead of items with a large quantity, it is possible to make a production plan that suppresses the variation in the number of production and efficiently uses the equipment.

(Other embodiments)
Although the present invention has been described with reference to the preferred embodiments and modifications, it should not be understood that the description and drawings constituting a part of this disclosure limit the present invention. From this disclosure, various alternative embodiments, examples, and operational techniques will be apparent to those skilled in the art.

  It goes without saying that the present invention includes various embodiments not described herein. Therefore, the technical scope of the present invention is defined only by the invention specifying matters according to the scope of claims reasonable from the above description.

1 is a system configuration diagram of a production plan output system and a functional block diagram of a production plan output device according to the preferred embodiment of the present invention. It is a hardware block diagram of the production plan output device which concerns on the best embodiment of this invention. In the best mode of the present invention, it is an example of data structure and data of cumulative quantity threshold value data showing the relation between the ratio of the cumulative quantity and the total number of days. In the best mode of the present invention, it is an example of the data structure and data of cumulative frequency threshold data showing the relationship between the ratio of cumulative frequency and the number of days ahead. In the best embodiment of this invention, it is a figure which shows an example of the data structure and data of lot summary data. In the best embodiment of this invention, it is a figure which shows an example of the data structure and data of advance days data. It is a flowchart explaining the process which outputs lot summary data in the lot summary advance days calculation means in the best embodiment of this invention. It is a flowchart explaining the process which outputs advance days data in the lot summary advance days calculation means in the best embodiment of this invention. It is a figure explaining the production quantity which processed by the production plan output apparatus of the best embodiment of this invention, and considered the lot summary and the advance days. It is a figure explaining an example of the relationship between the ratio of the request | requirement quantity and the accumulation quantity in the best embodiment of this invention. It is a figure explaining an example of the relationship between the ratio of the request frequency and the accumulation frequency in the best embodiment of this invention. It is the system block diagram of the production plan output system which concerns on the modification of the best embodiment of this invention, and the functional block diagram of a production plan output device. In the best mode of the present invention, it is an example of the data structure and data of correction threshold data showing the relationship between the corrected number of advance days determined based on the accumulated quantity and the accumulated frequency. It is a flowchart explaining the process of the advance days correction | amendment means in the modification of the best embodiment of this invention. It is the system block diagram of the conventional production plan output system, and the functional block diagram of a production plan output device. It is an example of the data structure and data of the production plan data output by the conventional production plan output device. It is an example of the data structure and data of the lot summary data referred with the conventional production plan output device. It is an example of the data structure and data of the advance days data referred by the conventional production plan output apparatus. It is a figure explaining the demand quantity and frequency for every item and request | requirement day which are referred with the conventional production plan output device. It is a figure explaining the production quantity which was processed by the conventional production plan output apparatus and considered the lot summary and the advance days.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1,900 ... Production plan output apparatus, 2,950 ... Core system, 11 ... Days calculation means, 12 ... Scheduler means, 13 ... Advance days correction means, 931 ... Scheduler means, 21, 911 ... Item master data, 22, 912 ... Demand data, 23, 913 ... WIP data, 24, 914 ... Manufacturing process data, 25, 915 ... Equipment capability data, 26, 916 ... BOM data, 27, 917 ... Work day calendar data, 28, 918 ... Parts inventory data 29, 919 ... Personnel plan data, 30 ... Threshold data, 30a ... Cumulative quantity threshold data, 30b ... Cumulative frequency threshold data, 30c ... Correction threshold data, 31, 920 ... Lot summary data, 32, 921 ... Advance days data, 33, 922 ... production plan data, 101, 901 ... central processing controller, 102 ... R M, 103 ... RAM, 104 ... input device, 105 ... display unit, 106 ... communication control device, 107 and 107a, 107 b, 907a, 907b ... storage device, 108 ... removable disk, 109 ... input-output interface, 110 ... Bus

Claims (5)

A production plan output program that, when information is input from an input device, is executed by a computer that processes the information while storing it in a register and a storage device, and outputs production plan data including items and quantities to be produced on a predetermined working day In
Demand data storage means for storing demand data associated with a request date and a requested quantity for each item in a storage device;
Threshold data storage means for storing cumulative quantity threshold data associated with the cumulative quantity and the number of days in the storage device;
Initializing the cumulative quantity, reading the demand data from the storage device, calculating the total requested quantity of all items in the target operating period for outputting the production plan data, Sorted in descending order of the requested quantity for each item, and for all the items in the sorted order, the requested quantity of a predetermined item is added to the accumulated quantity, and the accumulated quantity threshold value data is read from the storage device and calculated. Extracting the number of summary days associated with the ratio of the cumulative quantity added to the total required quantity of all the items, and associating the identifier of the item with the extracted summary days and storing it in the storage device as lot summary data Means for calculating the number of days in advance of lots that repeat the process of storing;
A production plan output program for causing a computer to execute scheduler means for reading the lot summary data from the storage device and outputting the production plan data. A production plan output program that, when information is input from an input device, is executed by a computer that processes the information while storing it in a register and a storage device, and outputs production plan data including items and quantities to be produced on a predetermined working day In
Demand data storage means for storing demand data associated with a request date and a requested quantity for each item in a storage device;
Threshold data storage means for storing cumulative frequency threshold data in which the cumulative frequency and the number of days ahead are associated with each other in the storage device;
Initializing the cumulative frequency, reading out the demand data from the storage device, calculating the sum of the request frequencies of all items in the target operating period for outputting the production plan data, and in the target operating period The items are sorted in descending order of the request frequency for each item, and for all items in the sorted order, the request frequency of a predetermined item is added to the cumulative quantity, and the cumulative frequency threshold data is read from the storage device. Further, the number of advance days associated with the ratio of the cumulative frequency added to the total of the request frequencies of all the items is extracted, and the identifier of the item and the extracted advance days are associated with each other in the storage device as advance day data. Means for calculating the number of days in advance of lots that repeat the process of storing;
A production plan output program for causing a computer to execute scheduler means for reading the advance days data from the storage device and outputting the production plan data. A production plan output program that, when information is input from an input device, is executed by a computer that processes the information while storing it in a register and a storage device, and outputs production plan data including items and quantities to be produced on a predetermined working day In
Demand data storage means for storing demand data associated with a request date and a requested quantity for each item in a storage device;
Threshold data storage means for storing cumulative quantity threshold data in which the cumulative quantity and the number of days to be associated are associated, and cumulative frequency threshold data in which the cumulative frequency and the number of days in advance are associated;
Initializing the cumulative quantity, reading the demand data from the storage device, calculating the total requested quantity of all items in the target operating period for outputting the production plan data, Sorted in descending order of the requested quantity for each item, and for all the items in the sorted order, the requested quantity of a predetermined item is added to the accumulated quantity, and the accumulated quantity threshold value data is read from the storage device and calculated. Extracting the number of summary days associated with the ratio of the cumulative quantity added to the total required quantity of all the items, and associating the identifier of the item with the extracted summary days and storing it in the storage device as lot summary data Repeat the process to memorize,
Initializing the cumulative frequency, reading out the demand data from the storage device, calculating the sum of the request frequencies of all items in the target operating period for outputting the production plan data, and in the target operating period The items are sorted in descending order of the request frequency for each item, and for all items in the sorted order, the request frequency of a predetermined item is added to the cumulative quantity, and the cumulative frequency threshold data is read from the storage device. Further, the number of advance days associated with the ratio of the cumulative frequency added to the total of the request frequencies of all the items is extracted, and the identifier of the item and the extracted advance days are associated with each other in the storage device as advance day data. Means for calculating the number of days in advance of lots that repeat the process of storing;
A production plan output program for causing a computer to execute the scheduler means for reading the lot summary data and the advance date data from the storage device and outputting the production plan data. The threshold data storage means further stores, in the storage device, corrected threshold data associated with a new advance date based on the cumulative quantity and the cumulative frequency,
Read lot summary data, advance date data, and correction threshold data from the storage device, extract new advance days based on the accumulated quantity and the accumulated frequency for all items as corrected advance days, and identifier of the item And the advance days correction means for repeating the process of storing the corrected advance days data in the storage device in association with the corrected advance days,
4. The production plan output program according to claim 3, wherein the scheduler means reads the lot summary data and the correction advance date data from the storage device and outputs the production plan data. When the information is input from the input device, the production plan output device outputs the production plan data including items and quantities to be produced on a predetermined working day, which is executed in a computer that processes the information while storing the information in a register and a storage device In
Demand data storage means for storing demand data associated with a request date and a requested quantity for each item in a storage device;
Threshold data storage means for storing cumulative quantity threshold data in which the cumulative quantity and the number of days to be associated are associated, and cumulative frequency threshold data in which the cumulative frequency and the number of days in advance are associated;
Initializing the cumulative quantity, reading the demand data from the storage device, calculating the total requested quantity of all items in the target operating period for outputting the production plan data, Sorted in descending order of the requested quantity for each item, and for all the items in the sorted order, the requested quantity of a predetermined item is added to the accumulated quantity, and the accumulated quantity threshold value data is read from the storage device and calculated. Extracting the number of summary days associated with the ratio of the cumulative quantity added to the total required quantity of all the items, and associating the identifier of the item with the extracted summary days and storing it in the storage device as lot summary data Repeat the process to memorize,
Initializing the cumulative frequency, reading out the demand data from the storage device, calculating the sum of the request frequencies of all items in the target operating period for outputting the production plan data, and in the target operating period The items are sorted in descending order of the request frequency for each item, and for all items in the sorted order, the request frequency of a predetermined item is added to the cumulative quantity, and the cumulative frequency threshold data is read from the storage device. Further, the number of advance days associated with the ratio of the cumulative frequency added to the total of the request frequencies of all the items is extracted, and the identifier of the item and the extracted advance days are associated with each other in the storage device as advance day data. Means for calculating the number of days in advance of lots that repeat the process of storing;
A production plan output device comprising: scheduler means for reading the lot summary data and the advance days data from the storage device and outputting the production plan data.

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