JP2008217653A - Efficient management support method of material procurement-production process - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an efficient management support method for enhancing the efficiency of a material procurement-production process by preventing production delay due to stock-out of materials and in-process products and shipping delay due to stock-out of product stock even when a sales plan is changed to rapidly increase sales, and preventing unnecessary stock of the materials and a product, the in-process product and the product while minimizing the money amount for the stocks. <P>SOLUTION: When the sales plan is changed, simulation data is formed based on product information, production information, a changed sales plan, and cumulative total value information including each cumulative total value of the number of materials for advance arrangement including a scheduled production quantity for each predetermined period and forecast information. Simulation is performed using a process model obtained by modeling the material procurement-production process based on the simulation data, and inventory forms in a plurality of work areas which never cause any stock-out when the sales plan is changed and can minimize the money amount of stocks and safe stock setting values of the stock quantities thereof are calculated. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to optimization of stocks of materials and products that do not hinder production even if a production plan changes due to a sales plan change in a material procurement / production process from material procurement to product.

  In the production of products, there are multiple business areas from procurement of materials (hereinafter also referred to as parts), through production processes, to product completion, such as material procurement, production, product inventory, and shipping management. A series of business activities are performed through coordination of business activities in each business area. In such a chain of business activities, that is, in the material procurement / production process, the efficiency is an important issue.

  In order to improve the efficiency of material procurement and production processes where multiple business areas exist, production perspectives such as production information such as production volume and delivery date, forms of procurement, production, logistics, etc. and information about their bases, etc. It is necessary to consider from.

  For this reason, in order to improve the efficiency of the material procurement / production process, it is possible to create a process model that models the material procurement / production process and perform simulation with a simulator to improve the efficiency of the material procurement / production process. Has been done.

  In addition, in the material procurement / production process, if there are weak parts in the process, such as the flow of information or information, such as unclear inventory quantity, the material procurement / production process may be disrupted. . Therefore, in order to optimize the flow of materials and information on business activities such as material procurement, production, and product inventory management from material procurement to product completion, the flow of materials is captured in real time for all operations in the process. Need to be. Therefore, introduction of an information system package called an ERP (Enterprise Resource Planning) package has been promoted for the core business of a company.

  The ERP package is an integrated business package, which is package software for an enterprise information system that integrates the entire enterprise activities such as sales, production, logistics, and finance. By integrating systems that were built separately for each department so that they can be referenced and used mutually, centralized management of data such as financial accounting and personnel, system upgrades and easy maintenance checks, Real-time reference of work in other departments is also possible.

  In the material procurement and production process, sales and production plans are prepared according to demand (orders), materials are procured from outside and other factories (hereinafter also referred to as suppliers), and production activities are carried out in the production process. Is called. When the material is procured, in addition to the material order confirmation information, in general, the procurement side (ordering side) notifies the supplier of the prospective material ordering information (forecast information) in order to facilitate the procurement. The forecast information is changed to material order confirmation information on a predetermined date. As a result, the supplier can make a future production plan, and it is possible to suppress the occurrence of excess inventory and shortage.

  However, the demand does not always stay constant, and the sales plan may vary. This causes production fluctuations when changing from forecast information to material order confirmation information. For this reason, especially in response to an increase in the sales plan, it prevents production delays due to material shortages and shipment delays due to insufficient product inventory, while preventing unnecessary inventory of materials and products and minimizing the amount of inventory. It is hoped that. Such optimization of inventory is an important factor for improving the efficiency of the material procurement / production process.

  On the other hand, the error of the past forecast information, the average value of the error, and the standard deviation of the error are calculated from the past forecast information and the order received corresponding thereto, and the current forecast information is corrected. The calculation of the order quantity is disclosed. (For example, refer to Patent Document 1).

  Also, the additional order quantity is calculated by the additional order quantity calculation means that determines the additional order quantity of the resource for the period based on the resource quantity of the resource at the time of use in the additional production. However, it is disclosed to place an order for a member (for example, see Patent Document 2).

In addition, for the production request, the management target period is set and the upper limit value in case of sudden increase in production is established by limiting the cumulative value management. (For example, refer to Patent Document 3).
JP 2006-39802 A JP 2006-155361 A JP 2006-113748 A

  Patent Document 1 corrects the current forecast information and calculates the order quantity, so that the order receiving side can make a highly accurate order prediction, thereby preventing the occurrence of shortage and excessive inventory. It is intended to effectively suppress. However, in the case of a sudden change in order, especially in the case of an increase in production, it is impossible to predict whether or not a shortage will occur.

  Patent Document 2 intends to calculate the additional order quantity by the additional order quantity calculation means, secure the parts while reducing unnecessary inventory as much as possible by placing the parts order, and to cope with fluctuations in the demand of the product. . However, it is only the calculation of the additional order quantity, that is, the additional manufacturable quantity, and when there is a sudden change in the order more than the additional manufacturable quantity, a shortage may occur.

  Japanese Patent Laid-Open No. 2004-228688 uses the cumulative number of scheduled productions and the cumulative number of parts arranged to determine the upper limit for sudden increase in production, and to manage parts advance arrangement (forecast information) and production number determination.

  However, even if such restrictions due to cumulative value management are imposed, the following measures are taken in order to cope with a sudden increase in production. In the material procurement business area (hereinafter also referred to as a material procurement department), materials (parts) having a long delivery lead time, that is, so-called long delivery parts, have a safety stock. In a production business area (hereinafter also referred to as a production department), a product with a long production lead time has a work-in-process and a product as a safety stock in the process.

  In this way, each department in the material procurement and production process has its own safety stock so that it can withstand the upper limit of the cumulative management value even if the management target period is set and restrictions are imposed by cumulative value management. There is no change in the structure, and there are many cases where there is an excessive number of inventory in the entire material procurement and production process. Along with this, the stock amount also increases.

  The present invention has been made in view of the above situation, and prevents a delay in production due to a shortage of materials and work-in-progress and a delay in shipment due to a shortage of product inventory even if there is a sudden change in sales plan. It is an object of the present invention to provide an efficient management support method that prevents unnecessary inventory of work-in-process and products and minimizes the amount of inventory to improve the efficiency of material procurement and production processes.

The above object is achieved by the following method.
1. From material procurement to production process, including production plan where material order information shifts from future material order forecast information (forecast information) to material order confirmation information, and production plan may change due to sales plan change An efficient management support method to improve the efficiency of material procurement and production processes consisting of multiple business areas that lead to products,
Setting on a computer a process model that models the material procurement / production process;
Creating and managing cumulative value information including each cumulative value of the number of material advance arrangements including the planned production number and forecast information for each predetermined period, and storing the cumulative value information in a storage means;
Based on the constraint conditions that restrict the sales plan fluctuation, the cumulative value information, and the production plan drafting, a variable production plan is created and stored as production plan fluctuation information in storage means;
The product information and the production information are extracted from an ERP (Enterprise Resource Planning) package in which product information and production information are stored, and the variable production plan is extracted from the storage means, and the product information, the production information, and the fluctuation Based on the production plan, the accumulated value information, creating the simulation data with simulation data creating means for creating simulation data, and storing in the storage means;
Using the process model, based on the simulation data, performing a simulation corresponding to the variable production plan with a simulator, causing no stockout when the production plan fluctuates, and inventory in the plurality of business areas that minimizes the stock amount Calculating a safety stock setting value for the form and its inventory quantity;
An efficient management support method for material procurement and production processes characterized by having
2. 2. The method for efficiently managing a material procurement / production process according to 1, wherein the plurality of business areas includes a material procurement business area and a production business area.
3. 3. The method for efficiently managing a material procurement / production process according to 1 or 2, wherein the stock form is a form of a material, work-in-process, or product while the material is an assembled product.
4). 4. The material procurement / production process according to any one of 1 to 3, wherein the product information includes material used for the product, the quantity of the material, a process chart of the product, and data of the configuration. Management support method.
5. 5. The production information according to any one of 1 to 4, wherein the production information includes production plan information of product production volume and delivery date, material inventory information, ordering information, delivery date information, price information, and product inventory information. To support efficient management of materials procurement and production processes.
6). In performing the simulation, taking out the material procurement / production process base information stored in the storage means, information on the communication environment status, communication environment information, and distribution information on the distribution status, and performing a simulation The efficient management support method for material procurement / production process according to any one of 1 to 5, characterized in that

  As a result of the above, it is possible to optimize the safety stock in response to sales plan fluctuations as a whole material procurement / production process, not individual departments. Can be effectively suppressed and the stock amount can be minimized.

  In addition, the supplier can obtain information on the results of the simulation from the ERP package, and can make future production plans. Even if production fluctuations due to sudden sales plan fluctuations occur, excess suppliers and missing items Occurrence can be suppressed.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited thereto.

  FIG. 4 is a table showing an example of changes in forecast information (hereinafter also referred to as forecast) and material order confirmation information (hereinafter also referred to as order confirmation). FIG. 4 shows an example in which the order interval, the forecast transmission interval, and the delivery lead time are set to one week. These intervals are appropriately set depending on the types of products and materials, and are, for example, two weeks or one month. The intervals may be different. In FIG. 4, the order confirmation is denoted as PO and the forecast as FC.

  In accordance with the production plan drafted by the initial order, PO1 of the final order is placed in the planned ordering week, and the forecast FC1 is transmitted. PO1 is delivered in 2 weeks. In 2 weeks, FC2 is changed to PO2 and an order is placed, and a forecast FC2 is transmitted. PO2 is delivered in 3 weeks. The same goes for the following. FIG. 4 shows an example in which delivery is completed in nine weeks.

  In the example of FIG. 4, the ordering is performed by creating a material requirement plan by MRP (Material Requirements Planning) or the like based on the production plan every week.

  FIG. 1 is a diagram illustrating an example of the configuration of the material procurement / production process 100. As described above, the material procurement / production process 100 generally includes a plurality of business areas, and is configured by a chain of the business areas. In the present embodiment, the business areas are divided into a supplier 110, a material procurement department 120, a production department 130, a product management department 140, and a production management department 150.

  The material procurement department 120 procures materials from the supplier 110 and manages the delivered materials. The production department 130 manages the materials in the production process and the product production. The product management department 140 The company has management of products before factory shipment and product shipment management.

  The production management department 150 creates a production plan based on the sales plan information (sales request) from the sales department 200, and has operations of performing and managing product production in a series of business chains of the material procurement / production process 100. . Further, based on the production plan, the cumulative value information of each cumulative value of the planned number of production for each predetermined period and the number of material advance arrangements including forecasts is created and managed. The pre-determined period is a unit period of the production plan, and is set as appropriate depending on the types of products and materials. For example, the period is a day unit or a week unit.

  The classification is not limited to the present embodiment, and is appropriately classified according to the procurement and production form of materials, product specifications, physical distribution form, sales form, and the like. In addition, although the range of the division is divided according to the business area in the present embodiment, it may be set for each organization or each base. Information on the configuration of the material procurement / production process 100 is also stored in the storage means.

  Figure 2 shows the procurement of materials from the procurement of materials through the production process to product shipment, including production plans in which the ordering information for materials shifts from forecast to finalization and production fluctuations may occur due to fluctuations in sales plans. It is a block diagram which shows one Embodiment of the efficient management assistance method which aims at efficiency of a production process.

  As described above, the material procurement / production process 100 generally includes a plurality of business areas, and is configured by a chain of the business areas.

  In FIG. 2, the database 1 is a storage means for storing the various data and information described above, and the data and information of the ERP package 2 are also necessary via the relay program 5 and the data conversion unit 6 that is a simulation data creation means. It is taken in according. In addition, simulation data created by the data converter 6 described later is also captured. Of the data and information of the ERP package 2, data and information that are not used by the data conversion unit 6 may be directly taken into the database 1 via the relay program 5 without using the data conversion unit 6.

  The ERP package 2 is an integrated business package, has an integrated database, and stores product information, production information, and the like. The product information is based on the materials used for the product, the quantity of the material, the process schedule and data of the product, etc., and the production information is the product production volume, production lead time, delivery date, material delivery route, delivery lead time, inventory. , Ordering, delivery date, price information, product inventory information, etc. In the present embodiment, SAP (R / 3) (registered trademark) manufactured by SAP is preferably used as the ERP package 2.

  Hereinafter, the ERP package 2 is also referred to as SAP (R / 3) (registered trademark).

  The sales plan creation unit 4 creates a sales plan according to the demand (order received). The sales plan creation unit 4 may be provided, for example, in the sales management department of the sales department 200 shown in FIG. The sales plan is transmitted to the production plan creation unit 3.

  Based on the sales plan, the production plan creation unit 3 creates a production plan in consideration of each constraint condition in material procurement, production process, and physical distribution. Restrictions on material procurement include material production capacity, material delivery lead time, and material ordering contracts with suppliers. The production process constraint conditions include production lead time, process maximum production capacity, process production capacity switching condition, and the like. Restrictions on logistics include product delivery lead time, logistics capacity, warehouse inventory capacity, and the like. The production plan creation unit 3 is provided in the production management department 150 shown in FIG.

  The sales plan and the production plan are input to the database 1 and the ERP package 2 via the relay program 5 and the data conversion unit 6.

  When a change occurs in the initial sales plan, the sales plan creation unit 4 creates a variable sales plan and transmits it to the production plan creation unit 3. The production plan creation unit 3 performs variable production based on the cumulative value information of each cumulative value of the number of material advance arrangements including the planned number of production and the forecast based on the above-mentioned variable sales plan, each constraint condition, and the above-described production plan. Create a plan.

  Here, by incorporating the cumulative value information at the time of creating the variable production plan, it is possible to calculate the quantity and the time of the material that can be processed in advance in correspondence with the variable production plan. In addition, it is possible to calculate the quantity required for additional arrangements and send forecast changes. The variable sales plan and the variable production plan are taken into the data converter 6.

  The data conversion unit 6 creates simulation data based on the variable sales plan and the variable production plan, and the product information and the production information stored in the ERP package 2. The simulation data includes, for example, data that classifies materials for each delivery lead time, data that classifies materials used for each unit that constitutes a product, production lead time that is assembled in the unit for each unit, and stocks in the unit Various data used for the simulation of the material procurement / production process 100, such as the in-process pattern and the inventory amount data, the combination pattern of the order parts, the inventory parts and the unit inventory, and the production lead time of the product in that case . The simulation data is input to the database 1. Here, the unit refers to a work in process in which parts are assembled to a certain level.

  By providing the data conversion unit 6 and connecting the data conversion unit 6 with the ERP package 2, the production plan creation unit 3 and the sales plan creation unit 4, it is possible to create simulation data using the latest information. For example, even when the design change occurs and the data of the ERP package 2 is corrected, the data conversion unit 6 can always create simulation data based on the latest data of the ERP package 2. Also, by creating simulation data in advance, it is possible to reduce the load for creating simulation data when performing a simulation, which will be described later, and to perform a quick simulation.

  A process model obtained by modeling the material procurement / production process 100 is set on the computer by the model creation unit 7 based on the simulation data based on information such as the configuration of the material procurement / production process 100 stored in the database 1. Is done.

  The process model is a simulation of the actual material procurement / production process 100 reproduced as a virtual process on a computer. The actual material procurement / production process 100 flow, operations, etc. can be simulated on a computer.

  The simulation condition setting unit 8 performs simulation such as simulation period, for example, to what period after the production fluctuation occurs due to sales fluctuation, setting of initial stock, parameter setting such as setting of production amount of unit period, etc. Set the conditions.

  In the simulation unit 9, a simulation is performed using the process model set by the simulator based on the simulation data and the simulation conditions.

  By the simulation, when the production plan is changed, the material procurement / production process 100 as a whole can cope with the production plan change, that is, the material, the production delay due to the shortage of work in progress and the shipment delay due to the shortage of product inventory, Calculate the number of safety stocks for work-in-progress and products that minimize the stock value. In other words, the inventory form and the number of stocks that can cope with production plan fluctuations and minimize the stock amount are calculated in the entire plurality of departments (business areas) constituting the material procurement / production process 100. The safety stock number and the safety stock amount that is the stock amount are set as a safety stock set value. Based on the safety stock setting value, the safety stock of each department is set.

  Here, when the safety stock number is calculated without considering the stock amount, the stock amount of the safety stock number may not be minimized. This is because the amount of money varies depending on whether it has stock as a material, stock as work in progress, or stock as a product. Therefore, the inventory form is converted into the amount of incorporation into the safety stock quantity, and the amount is calculated to be the minimum amount.

  With the above, safety stock optimization that can cope with changes in production plans in the material procurement / production process 100 can be performed not for each department but for the entire material procurement / production process 100. It is possible to effectively suppress stockouts and excess inventory of materials, work-in-progress and products, and minimize the stock amount.

  The simulation data is always created by the data conversion unit 6 based on the latest data of the ERP package 2, the production plan creation unit 3 and the sales plan creation unit 4 as described above. For this reason, simulation close to an actual system and with high accuracy becomes possible.

  At the time of the simulation, a simulation is performed by taking out from the database 1 information of the bases constituting the material procurement / production process 100, information on the communication environment and communication environment information, and distribution information on the state of distribution. It is preferable. This makes it possible to perform a simulation that is closer to the actual system and with high accuracy.

  The result evaluation unit 10 evaluates and examines the results of the simulation (the number of safety stocks, the amount of safety stock), and if it is necessary to change the conditions and perform simulation, the conditions are set again by the simulation condition setting unit 8 and the simulation is performed. It can be performed. Thereby, the range of evaluation can be expanded.

  Information on the simulation result is fed back as a safety stock set value, stored in the database 1, and further transferred to the ERP package 2 via the data converter 6 and the relay program 5 for reflection. Note that the data may be transferred from the database 1 directly to the EP package 2 via the relay program 5 without going through the data converter 6.

  The simulation result transferred to the ERP package 2 is taken into the material procurement / production process 100 and reflected in the actual material requirement plan creation, order confirmation, and forecast.

  FIG. 3 shows an example of a flowchart for improving the efficiency of the material procurement / production process 100 using the efficiency improvement support method of the material procurement / production process 100 shown in FIG. It is assumed that necessary data and information are captured from the ERP package 2 in the database 1.

  In step S101, the sales plan creation unit 4 creates a variable sales plan.

  In step S102, the production plan creation unit 3 creates a variable production plan based on the variable sales plan created in step S101. The variable production plan is created by incorporating the above-described constraint conditions and cumulative value information.

  In step S103, the data converter 6 creates simulation data based on the variable sales plan and the variable production plan, and the product information and production information data of the ERP package 2.

  In step S104, a process model is created on the computer based on information such as the configuration of the material procurement / production process 100 stored in the database 1 by the model creation unit 7. A plurality of the process models are created in combination patterns including order parts, inventory parts, unit inventory, and product inventory based on the simulation data created in step S103.

  In step S105, the simulation condition setting unit 8 sets the simulation conditions by the person in charge. The setting of the simulation conditions includes a simulation period, an initial inventory setting, a parameter setting such as a production amount setting for a unit period, and the like.

  In step S106, the simulation unit 9 performs a simulation using the process model, and calculates, as a simulation result, the number of safety stocks that can cope with the variable production plan and minimize the stock amount of materials, work-in-process, and products.

  In step S107, the result evaluation unit 10 evaluates and examines the simulation result (safety stock set value). Further, if it is necessary to change the conditions for the simulation (step S107; NO), the conditions are set again in step S105 and the simulation is performed. If re-simulation is not required (step S107; YES), the simulation result is stored in the database 1 in step S108.

  In step 109, the simulation result is transferred from the database 1 to the ERP package 2 and reflected in the data and information of the ERP package 2.

  As a result of the above, when the sales plan fluctuates, it is possible to optimize the entire material procurement / production process, not the individual optimization of each business area (each department) in the material procurement / production process. Stockouts and excess inventory can be effectively suppressed and the amount of inventory can be optimized.

  In addition, the supplier can obtain information on the simulation results from the ERP package 2 and can make future production plans. Even if production fluctuations occur due to sudden sales plan fluctuations, excess stock and missing items Can be suppressed.

It is a figure which shows an example of a structure of material procurement and a production process. It is a block diagram which shows an example of the efficient management support method of the material procurement and production process which concerns on this invention. It is a figure of a flowchart which shows an example of the efficient management support method of the material procurement and production process which concerns on this invention. It is a figure which shows transition of forecast information and material order confirmation information.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Database 2 ERP package 3 Production plan creation part 4 Sales plan creation part 5 Relay program 6 Data conversion part 7 Model creation part 8 Simulation condition setting part 9 Simulation part 10 Result evaluation part 100 Material procurement / production process 110 Supplier 120 Material procurement department 130 Production Department 140 Product Management Department 150 Production Management Department 200 Sales Department

Claims (6)

From material procurement to production process, including production plan where material order information shifts from future material order forecast information (forecast information) to material order confirmation information, and production plan may change due to sales plan change An efficient management support method to improve the efficiency of material procurement and production processes consisting of multiple business areas that lead to products,
Setting a process model that models the material procurement / production process on a computer;
Creating and managing cumulative value information including each cumulative value of the number of material advance arrangements including the planned production number and forecast information for each predetermined period, and storing the cumulative value information in a storage means;
Based on the constraint conditions that restrict the sales plan fluctuation, the cumulative value information, and the production plan drafting, a variable production plan is created and stored as production plan fluctuation information in storage means;
The product information and the production information are extracted from an ERP (Enterprise Resource Planning) package in which product information and production information are stored, and the variable production plan is extracted from the storage means, and the product information, the production information, and the fluctuation Based on the production plan, the accumulated value information, creating the simulation data with simulation data creating means for creating simulation data, and storing in the storage means;
Using the process model, based on the simulation data, performing a simulation corresponding to the variable production plan with a simulator, causing no stockout when the production plan fluctuates, and inventory in the plurality of business areas that minimizes the stock amount Calculating a safety stock setting value for the form and its inventory quantity;
An efficient management support method for material procurement and production processes characterized by having The method for efficiently managing a material procurement / production process according to claim 1, wherein the plurality of business areas include a material procurement business area and a production business area. The method for efficiently managing a material procurement / production process according to claim 1 or 2, wherein the inventory form is a form of a material, work-in-progress, or product while the material is an assembled product. The material procurement / production process according to any one of claims 1 to 3, wherein the product information includes data used for the product, the quantity of the material, a process chart of the product, and data of the configuration. Efficient management support method. 5. The production information according to claim 1, wherein the production information includes production plan information of product production amount and delivery date, material inventory information, ordering information, delivery date information, price information, and product inventory information. Efficient management support method for material procurement and production process described in 1. In performing the simulation, taking out the material procurement / production process base information stored in the storage means, information relating to the communication environment state, communication environment information, and distribution information relating to the distribution state, and performing a simulation 6. The efficient management support method for a material procurement / production process according to claim 1, wherein the material procurement / production process is effective.

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