JP2008165498A - Manufacturing and physical distribution planning system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To make a manufacturing plan enabling more efficient delivery. <P>SOLUTION: A manufacturing plan formulating a manufacturing schedule for ordered articles in each process of a manufacturing line S is made in accordance with order acceptance information and manufacturing constraints. A transportation plan is developped as to products close to delivery, and the manufacturing schedule for each product in the manufacturing plan is corrected in accordance with the scheduled shipping date of the product in the plan. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention manufactures the above manufacturing plan and transportation plan when manufacturing according to the manufacturing plan on a production line capable of manufacturing a plurality of types and transporting the manufactured articles of a plurality of types with a transporting device according to the transportation plan.・ It relates to logistics operation system. In particular, it is suitable for application to a build-to-order production system.

  Products and semi-finished products manufactured in the factory are transported to the customer and another factory using a transport device (vehicle, ship, aircraft, etc.). Usually, in consideration of transportation efficiency, a form is used in which a plurality of products and semi-finished products (in many cases, for a plurality of customers) are loaded and transported together (hereinafter this summary). The transported baggage is called a transport lot.) Since logistics efficiency varies greatly depending on which products and semi-finished products are put together, in general, a transportation plan is made in advance to ensure efficient logistics for products that have already been manufactured or just completed, and actual transportation work is performed accordingly. Is done.

Here, the packages included in the transportation lot are products and semi-finished products manufactured at the factory. For this reason, when manufacturing multiple products in parallel at the factory, the combination of packages in each transportation lot that matches the destination and date of shipment depends on the manufacturing order of products and semi-finished products at the factory. Become.
However, in the past, since it was complicated to create a manufacturing plan and a transportation plan at the same time and it took a long time to calculate, the manufacturing plan and the transportation plan were often prepared separately.

As a technique related to this planning method, for example, there is one described in Patent Document 1. In this patent document 1, the planning method which cooperated manufacture and conveyance is proposed. The main point of the technology of the patent document 1 is that the optimal production delivery date (delivery date convenient for logistics) after the creation of the transportation plan to reduce the inventory by linking the planning of manufacturing and transportation, which were conventionally separately planned, A production plan is created using two kinds of parameters of the latest production delivery date, and then a transport re-plan is performed.
JP 2004-341646 A

In the technique of the above-mentioned patent document 1, the latest production delivery time is calculated from the transportation lead time required from the completion of the product to the arrival of the product at the destination and the requested delivery date of the customer. However, the time required for transportation cannot be accurately calculated only by the transportation lead time.
For example, even if a package is prepared on the latest production delivery date for the following reasons, the package may not be transported. That is, in such a case, there is a problem in that it may not be possible to carry the product on the latest production delivery date, and the customer's requested delivery date may not be observed.
1) Due to lack of transportation equipment on the day of the latest production delivery date.
2) The cargo for one transport device is not available (the transport lot does not become large).
The present invention has been made paying attention to the above points, and it is an object of the present invention to make a production plan capable of more efficient delivery.

In order to solve the above-mentioned problems, the invention described in claim 1 of the present invention is manufactured according to a manufacturing plan on a production line capable of manufacturing a plurality of types of articles, and the manufactured plurality of types of articles are transported. A production / distribution plan creation system for creating the above-mentioned production / distribution plan when transported by a transportation device according to a scheduled shipping date,
A production plan creation means for creating a production plan in which a production schedule is formulated in each process of the production line for the ordered item based on the order information, the production constraint condition, and the production progress information;
Develop a transportation plan based on order information and transportation constraints for articles that can be shipped, or articles that can be shipped and items that can be shipped within a specified period,
The present invention is characterized by comprising manufacturing schedule correcting means for correcting the manufacturing schedule of each manufactured article in the manufacturing plan data obtained by the manufacturing plan creating means based on the scheduled shipping date according to the transportation plan draft.

Next, the invention described in claim 2 is manufactured according to a manufacturing plan on a manufacturing line capable of manufacturing a plurality of types of articles, and the manufactured plurality of types of articles are transported by a transport device according to a scheduled shipping date of the transport plan. A production / distribution plan creation system for creating the above-mentioned production / distribution plan,
A production plan creation means for creating production plan data in which the order and combination of the processing of articles to be manufactured are formulated based on the order information and the production constraint conditions;
A transportation plan drafting means for creating a transportation plan draft based on the order information, the transportation constraint condition and the manufacturing progress information;
Shipping request information creating means for creating shipping request information for each article based on a transportation plan;
A production plan correction means for correcting the production plan data created by the production plan creation means based on the shipping request information and the production constraint conditions;
It is characterized by providing.

Next, the invention described in claim 3 is the configuration described in claim 2, wherein the shipping request information includes at least the first scheduled shipping date of the target article based on the delivery date, and one or more. It is characterized by having the scheduled transfer date.
Next, the invention described in claim 4 is characterized in that, in contrast to the configuration described in claim 3, the shipping request information includes at least a surplus load value to the transporting device corresponding to the scheduled date of transfer shipment. To do.
Next, the invention described in claim 5 is an article that can be shipped based on the manufacturing progress of each article, or an article that can be shipped, with respect to the configuration described in any one of claims 2 to 4. It is characterized by comprising a transportation plan creation means for judging an article that can be shipped within a predetermined period and creating a transportation plan based on the judgment result.

According to the present invention, for the production schedule of at least the lower process of the production plan, the order of production and the combination are corrected as much as possible along the shipment schedule by the shipment schedule based on the provisional transportation plan draft. A production plan capable of efficient delivery can be drawn up.
Furthermore, the accuracy of the manufacturing / transportation plan can be further increased by obtaining the surplus information of the transport lot.
In addition to logistics efficiency, there is an advantage that inventory costs can be reduced by reducing the amount of inventory if the production and logistics are operated well together.

Next, embodiments according to the present invention will be described with reference to the drawings.
In the following description, a case where a product (article) manufactured in a factory is loaded on a ship (transportation device) and transported will be described as an example. In general, transportation using a carrier ship has a larger amount of luggage to be carried at one time than transportation using a transportation vehicle, and takes a longer time for a transportation cycle. For this reason, the intervals (hours, days) that transport ships heading for a specific destination are often longer than those of transport vehicles. In order to transport each product in time for delivery, It is necessary to make a transportation lot well.

(Constitution)
FIG. 1 is a diagram showing a schematic configuration of a manufacturing / distribution plan creation system according to the present embodiment.
The manufacturing line manufactures a plurality of types of articles from the upper process to the lower process in the order and combination according to the manufacturing plan, and the manufactured products are stored in a warehouse.
In the logistics facility, considering the shipping date, transport destination, and loading capacity of each transport ship in accordance with the transport plan, as shown in FIG. It is loaded onto the target carrier using a crane or other cargo handling equipment. The transport ship sails to the destination, the unloading port, and after arrival, the product is unloaded by a crane or the like. The unloaded products are stored in a warehouse at the unloading port and then delivered to the customer using a transport vehicle such as a trailer or truck.

And in the system of this embodiment, as shown in FIG. 1, as a processing apparatus, the manufacturing plan preparation part 1, the manufacturing plan correction | amendment part 2, the conveyance plan draft preparation part 3, the shipping request information preparation part 4, the progress management part 5 And a transportation plan creation unit 6.
Also, an order information file 10 that stores information related to an order requested by a customer, a transport constraint condition storage file 11 that stores transport constraint conditions that are constraints on ship transportation, and a manufacturing constraint that stores manufacturing constraint conditions A condition storage file 12 and a progress management file 13 storing information on the manufacturing status of each product are provided.

The order information included in the order information file 10 includes customer name, product type, product size (weight, length, width, etc.), factory in charge of production (ship port), delivery date, destination (lift port), transportation ideal The ship type. The ideal ship type is designated when the type of product or the type of ship that can be used is limited depending on the port of loading and unloading.
The constraint information contained in the transport constraint condition storage file 11 includes a loading port list, a transport ship list, a cargo handling crane list, and characteristics of the transport ship (shipping, maximum loadable weight, loadable product type, voyage speed, non-portable port information). List), distance between ports, list of ship types usable at each port, cargo handling efficiency (tons / hour) of cargo handling cranes, inventory capacity at each port, average transport lead time from each port to each customer, etc. .

The progress management file 13 stores information on the current status of each product (whether it has been completed and stored in a warehouse, or is incomplete and on some production line S).
The manufacturing plan creation unit 1 formulates the order and combination of processing of articles to be manufactured in each process based on the order information and manufacturing constraint conditions, and stores the determined manufacturing plan data in the manufacturing plan file 14. For example, the scheduled production date is determined in order from the lower process to the upper process based on the required man-hours of the manufactured article, interference with other manufactured articles, etc., and further the scheduled production date from the upper process to the lower process Are corrected in order. This is repeated to set the scheduled production date for each process of each article.

The progress management unit 5 stores in the progress management file 13 information on the completion of manufacturing of each article and at what stage of manufacturing based on information from the production line S and information on products stored in the warehouse.
The transportation plan drafting unit 3 is based on order information, transportation constraint conditions, and manufacturing progress information. Create a plan. That is, for products that may be completed in the near future based on progress information (products that are being manufactured in the lower process line) and for which the delivery date is approaching based on the order information, taking into account the transport constraints, A transportation plan plan including a ship on which a transportation lot scheduled to include each product is loaded and a shipping date of the ship is created and stored in the transportation plan file 15. This transportation plan is a provisional transportation plan.

  The shipping request information creation unit 4 refers to the transportation plan file 15 and creates shipping request information data for each product that will be shipped in the near future, and stores it in the shipping request information file 16. The shipping request information data includes the scheduled shipping date of the transportation lot scheduled to contain the product, the scheduled transfer date when the transportation lot to the ship to the same transportation location before and after, and the scheduled shipping date Is set as a transport surplus value (a surplus power that can be loaded). In some cases, shipping priority information is also added for each product.

The production plan correction unit 2 refers to the shipping request information file 16 and corrects the production plan of the lower process line of the production line S with respect to the production plan data in the production plan file. This correction is performed by changing the processing order and combination of each product so that the manufacturing is completed on the scheduled date of shipment.
The process is performed, for example, as shown in FIG.
That is, for each target product, first, in STEP 10, referring to the planned shipping date and the planned manufacturing completion date based on the current manufacturing plan, it is determined whether or not the manufacturing is completed on the planned shipping date. If determined, the process is terminated without correction.

If it is determined in step S10 that it is not in time, in step S20, the processing order and the combination of processes are changed in consideration of the manufacturing delivery date and other constraints of other products. Check if the manufacturing can be completed in time using an optimization method, etc., and if it can be changed, change the manufacturing plan to the processing order or processing combination selected in step S25 and terminate the processing. To do.
If it is determined in step S20 that the change cannot be made, in step S30, it is determined whether or not the completion of production is in time for the scheduled transfer shipment date with reference to the scheduled transfer completion date and the scheduled production completion date based on the current production plan. If it is determined that it is in time, the process proceeds to step S40.

If it is determined in step S30 that it is not in time, if there is another possible transfer shipment date in step S35, the transfer shipment date is set and the process returns to STEP 30. On the other hand, if it is determined that none of the scheduled transfer shipping dates is in time, the process proceeds to step S100.
In step S40, when it is determined that loading is possible with reference to the corresponding conveyance surplus value, the process ends without changing. If not, the process proceeds to step S50, and if there is another possible transfer shipping date, the transfer shipping date is set and the process returns to STEPS 30. Otherwise, the process is terminated as it is.

In step S100, it is determined whether or not there is a scheduled transfer date with a surplus value that can be loaded with the corresponding load. If it is determined that there is a transfer date, the process proceeds to step S110. If not, the process ends without changing.
In step S110, regarding the scheduled transfer date with a surplus value capable of loading the corresponding load, the transfer order is changed by changing the processing order and the processing combination in consideration of the production delivery date of other products and other constraints. Check whether the manufacturing can be completed in time for the scheduled shipping date, using an optimization method, etc., and if it is determined that it can be changed, change the manufacturing plan to the processing order or processing combination selected in step S115. The process is terminated. On the other hand, if it is determined that it is not in time, the process is terminated without changing.

The transportation plan creation unit 6 refers to the progress management file 13 to determine a product that can be shipped, and based on the determination result, refers to the order information and creates an implementation transportation plan under transportation constraint conditions. .
In this transportation plan, information such as transportation lot creation of each product, transportation lot loading date and time, used cargo handling crane, and transportation ship to be used is set.
Here, the production plan creation unit 1 constitutes a production plan creation unit, the production plan correction unit 2 constitutes a production plan correction unit, the transportation plan draft creation unit 3 constitutes a transportation plan draft creation unit, and shipping request information The creation unit 4 constitutes a shipping request information creation unit, the transportation plan creation unit 6 constitutes a transportation plan creation unit, and the transportation plan draft creation unit 3, the shipping request information creation unit 4, and the manufacturing plan correction unit 2 are manufactured. Schedule correction means is configured.

(Function and effect)
In the plan creation system with the above configuration, a production plan including the production schedule and production delivery date of each component of each product is drawn up based on the order information. This production plan is from the start of production to the completion of production. Considering this period, for example, it is planned half a month before the customer delivery date, so that the contents are relatively rough, and there is little or no consideration of the plan on the logistics side.
On the other hand, in this embodiment, if the manufacturing schedule of the lower process of manufacturing can be replaced or combined with other products in accordance with the logistics plan forecast on the logistics side, the manufacturing schedule will be Make a change. As a result, the production order is changed so that it is easy to carry, thereby improving the efficiency on the logistics side. That is, for example, it is possible to reduce a decrease in the load amount of the load on the ship at the same transportation destination.

(Example of correcting the manufacturing plan in the manufacturing process above)
As manufacturing reference information, the following three types are used.
(1) Scheduled shipping date for transportation lots that include packages in the transportation plan draft (2) Candidate shipping date for transfer transportation lots derived from transportation planning plans (3) Transfer transportation lots derived in transportation planning plans Here, it is assumed that the transportation plan creation unit 6 creates a plan for products to be shipped from the next day to 5 days after the plan creation date (N day) (N + 1 day to N + 5 day). Further, as shown in FIG. 4, it is assumed that the plan creation is executed every day. And the example of the produced conveyance plan result is shown in FIG.

An example of how to obtain the information (1) to (3) regarding “Product A” for Osaka will be described below.
Product A has lot no. Since the shipping date of this lot is 21 days, the shipping date of (1) is 21 days. Next, (2) shows that product A has a transportation lot No. If it is not in time for 1132, it means shipment date list information in the case of carrying in another transportation lot. Since product A can be included only in the transportation lot for Osaka, the candidate for the transfer transportation lot is the transportation lot number. 1133, NO. 1134, NO. 1135. However, in order to meet the delivery date, the product A needs to be shipped by the 23rd (since the latest shipping date is the 23rd). 1133, NO. 1134 is a transfer transportation lot, and the candidate shipment dates of (2) are 22 days and 23 days. In order to include the product A in the transfer transportation lot, it is necessary to have a surplus capacity in the transfer transportation lot (even if the product A is added, the lot does not exceed the capacity of one ship). (3)
The remaining capacity is calculated for each transfer transportation lot listed in (2).

Transportation lot No. Assume that 1133 is in the state shown in FIG. There are the following two types of products included in the transportation lot of the transportation plan.
・ Products that have already been manufactured at the time of planning and can be shipped (stock items)
・ Products that are not yet produced at the time of planning (unstocked)
Moreover, unstocked goods can be classified into the following two types.
・ Products that cannot be delivered unless they are transported in the included transportation lots (emergency products)
・ Non-emergency products (non-emergency products)

  If the transport lot weight does not reach the ship's loadable capacity of 100%, it can be said that the ship has a margin for loading another load (ship vacancy: transport capacity value). A ship's vacancy is just the room to load, and non-emergency non-emergency items can be thought of as an allowance for loading other packages instead by carrying them in a later lot (although the same unloading port). it can. Therefore, if the unoccupied vehicle non-emergency goods and the vacant space of the ship are used as the transport surplus value, it is calculated as shown in FIG. 6 and the transport surplus value is 900 tons. Transportation lot No. The same calculation is performed for the conveyance surplus value 1134.

The shipping request information of (1) to (3) is stored in the DB and used when creating a manufacturing plan. For example, when it is difficult to complete the manufacture of the product A within 20 days, the date of the manufacture is determined based on the shipping request information. For example, assume that there is the following shipping request information.
・ Product A can be shipped in transfer transportation lots on the 22nd and 23rd (information on (2))
・ The 22 days shipping lot has a transport capacity of 900 tons, and the 23 days shipping lot has a transport capacity of 50 tons (information in (3)).

  The 23-day shipping lot has a small carrying capacity value. For this reason, when priority is given to other products, there is a high possibility that the product A cannot be carried in the 23-day shipping lot (NO. 1134). Therefore, it is necessary to ship the product A in the 22-day shipping lot (NO. 1133) at the latest. In order to be in time for shipment on the 22nd, the manufacture of the product A needs to be completed within the 21st. A manufacturing plan is created while making such a determination. The produced production plan is sent to the production line S. The products manufactured on the line enter the warehouse and the information is stored in the DB file as inventory information.

Thereafter, a transportation plan (for one day) of inventory interior goods obtained from the inventory information DB file is created by the computer. The information included in the plan created here is the same as the plan for creating the transportation schedule. The created plan is stored in the final transportation plan DB and is called up when the shipping operation is executed.
Next, the following two methods are used to compare the delays in delivery when planning transportation and manufacturing.
(Comparison Method 1) A production plan is created using information on both the date of transportation and the latest shipment date.
(Method 2 of this embodiment) A production plan is created using the shipping request information.

Three types of products shown in FIG. The production plan creation date is N-1 days, and a production plan of N to N + 3 days is made. In addition, since the manufacture of emergency goods is already scheduled on the N day, the three types of products in FIG. 7 are to be manufactured during the N + 1 to N + 3 days. Since it takes 24 hours to manufacture each product, if it is manufactured on N + 1 days, the shipping date will be N + 2 days, so product A cannot be shipped according to the transportation plan. Since one of the products B and C will be manufactured after N + 2 days, shipment will be after N + 3 days. Using the method of comparison, paying attention only to the optimum production delivery date (one day before the planned shipment date) and the latest production delivery date (one day before the latest shipment date), considering the order of the latest production delivery date and the setup change cost Suppose that the manufacturing date is determined as follows.
Product A: N + 3 days production (shipped after N + 4 days)
Product B: N + 1 day production (shipped after N + 2 days)
Product C: N + 2 days production (shipped after N + 3 days)

Here, it is assumed that the details of the transportation plan created in consideration of the movement and the like of the ship are as shown in FIG. If manufacturing is performed according to the above plan, the product A will arrive at the port α after N + 6 days, resulting in a delay of delivery of one day or more. In addition, the products B and C are in time for delivery.
On the other hand, in the method 2 of this embodiment, since there is shipment request information, the delivery delay can be made zero by the following plan.
Product A: N + 1 day production (N + 2 day shipment) ... Transportation lot No. Transport product B at TT02: N + 3 day production (N + 4 day shipment) TT04 transported product C: N + 2 day production (N + 3 day shipping) Transport with TT05

It is a figure which shows the system structure outline | summary which concerns on embodiment based on this invention. It is a figure explaining the outline | summary of the physical distribution equipment B which concerns on embodiment based on this invention. It is a figure which shows the process example of the manufacturing plan correction | amendment part 2 which concerns on embodiment based on this invention. It is a figure explaining the plan object day in an Example. It is a figure which shows the conveyance plan result in an Example, and the image of a conveyance lot. It is a figure explaining the example of calculation of the conveyance surplus value of a transfer conveyance lot. It is a figure which shows the example of the manufacture scheduled product information in an Example. It is a figure explaining the conveyance plan result in an Example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Manufacturing plan preparation part 2 Manufacturing plan correction | amendment part 3 Transportation plan draft preparation part 4 Shipping request information preparation part 5 Progress management part 6 Transportation plan preparation part 10 Order receipt information file 11 Transportation restriction condition storage file 12 Manufacturing restriction condition storage file 13 Progress management File 14 Production plan file 15 Transportation plan file 16 Shipping request information file B Logistics equipment S Production line

Claims (5)

Manufacturing that creates the above manufacturing / distribution plan when manufacturing multiple types of goods according to the manufacturing plan on a production line that can be manufactured and transporting the manufactured multiple types of goods with a transport device according to the scheduled shipping date of the transport plan A logistics planning system,
A production plan creation means for creating a production plan in which a production schedule is formulated in each process of the production line for the ordered item based on the order information, the production constraint condition, and the production progress information;
Develop a transportation plan based on order information and transportation constraints for articles that can be shipped, or articles that can be shipped and items that can be shipped within a specified period,
A production / distribution plan creation system comprising production schedule correction means for correcting the production schedule of each manufactured article in the production plan data obtained by the production plan creation means based on a scheduled delivery date according to a transportation plan. Manufacturing that creates the above manufacturing / distribution plan when manufacturing multiple types of goods according to the manufacturing plan on a production line that can be manufactured and transporting the manufactured multiple types of goods with a transport device according to the scheduled shipping date of the transport plan A logistics planning system,
A production plan creation means for creating production plan data in which the order and combination of the processing of articles to be manufactured are formulated based on the order information and the production constraint conditions;
A transportation plan drafting means for creating a transportation plan draft based on the order information, the transportation constraint condition and the manufacturing progress information;
Shipping request information creating means for creating shipping request information for each article based on a transportation plan;
A production plan correction means for correcting the production plan data created by the production plan creation means based on the shipping request information and the production constraint conditions;
Manufacturing and distribution plan creation system characterized by comprising.   3. The manufacturing / distribution plan according to claim 2, wherein the shipping request information includes at least a first scheduled shipping date of an object based on a delivery date, and one or more scheduled transfer shipping dates. Creation system.   4. The manufacturing / distribution plan creation system according to claim 3, wherein the shipping request information includes at least a surplus capacity value to be loaded on a transporting device corresponding to a scheduled transfer shipping date.   It is provided with a transportation plan creation means for judging an article that can be shipped based on the manufacturing progress of each article, or an article that can be shipped and an article that can be shipped within a predetermined period, and creating a transportation plan based on the determination result. The manufacturing / distribution plan creation system according to any one of claims 2 to 4.

Images