JP2009129089A - Device for creating production plan - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To produce components according to a request from a post-process, even when there are variations of requests from the post-process, and a pre-process does not have sufficient production capacity. <P>SOLUTION: There provided are: storage sections 11, 12 for storing production plan information indicating a production plan in the post-process, production instruction information in the pre-process; and component configuration information indicating the correspondence between article number information of products to be produced in the post-process and the article numbers of components to be produced in the pre-process; and a request processing section 14 for identifying the article numbers of the components corresponding to the article numbers of the products on the basis of the component configuration information and generating request information identifying the number of components to be produced for each of production dates. A production instruction creation section 17 compares the number of components to be produced included in the request information and the number of the components which can be produced for each of the production dates in the pre-process, and when the number of the components to be produced included in the request information exceeds the number of the components which can be produced, selects components to be produced before the production dates, decides production dates for producing the components in advance, and updates production instruction information. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a production plan creation device that creates a production plan in each process of a product produced through a plurality of processes.

Conventionally, as a method for producing the required amount of products in a timely manner according to customer requirements, the production process according to the pulling (request) of the subsequent process is requested to the previous process. There is known a technique for linking between a process and a post-process.
JP-A-1-188256

  As described above, in order for the previous process to produce parts according to the requirements of the subsequent process, the required quantity of the subsequent process is stable, and the manufacturing capacity of the previous process is high even if the required quantity of the subsequent process is large. It is necessary to be sufficient. When such a condition is not satisfied, an environment in which a production system for the previous process can be constructed at any time according to a request for the subsequent process is required.

  In particular, in the manufacturing industry such as the home appliance industry, it is required to produce a wide variety of products in a short amount of time with a short delivery time. As described above, it is unavoidable that the requirements of the post-process are unstable, and it is not realistic to build a system that has sufficient manufacturing capability in the pre-process in consideration of cost.

  Furthermore, in order to complete one product, there are a large number of processes, and it is extremely troublesome to construct a production plan so that the delivery date is not delayed in all the processes. Therefore, in reality, when the demand for a certain product exceeds the production capacity, it is necessary to shift the delivery date of other parts, and this decision is left to the person in charge of each process. is there.

  Therefore, the present invention has been proposed in view of the above-described circumstances, and parts can be produced in accordance with the requirements of the subsequent process even if the requirements of the subsequent process vary and there is not sufficient manufacturing capability in the previous process. An object is to provide a production plan creation device.

  The present invention is performed in a post-process in a production plan creation apparatus that manages a production process having a pre-process for producing a product part and a post-process for producing a product using the part produced by the pre-process. Part configuration information that indicates the correspondence between production plan information that represents the production plan of the product, production instruction information for parts that are required in the previous process, product number information for products that are produced in the subsequent process, and part numbers that are produced in the previous process And a request information that specifies the part number corresponding to the product number included in the production plan information based on the part configuration information, and specifies the number of parts produced in the previous process for each production date. A request processing unit to be generated. In order to solve the above-mentioned problem, this production plan creation device uses the production instruction creation unit to produce the number of parts included in the request information generated by the request processing unit, and the number of products that can be produced per production date of the previous process. If the number of parts included in the requirement information exceeds the production capacity, the number of parts produced in the requirement information exceeds the production capacity. A part to be produced before the production date is selected, a production date for producing the part in advance is determined, and production instruction information is updated.

  According to the production plan creation device according to the present invention, the number of requested parts is compared with the number of products that can be produced for each production date in the previous process, and the number of parts requested exceeds the number of products that can be produced. If the part is produced on the production date that exceeds the production capacity, select the part to be produced before the production date, and determine the production date to produce the part ahead of schedule. Since the instruction information is updated, it is possible to produce parts in accordance with the requirements of the post-process even if there are variations in the requirements of the post-process and there is not sufficient manufacturing capability in the pre-process.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  A production plan creation device 1 to which the present invention is applied, as shown in FIG. 1, for example, acquires various information related to a pre-process and a post-process in a product production process and supplies a production instruction to the pre-process. .

  The production plan creation device 1 updates the production plan for the previous process from the production plan for the previous process and the production plan for the subsequent process. The production process managed by the production plan creation device 1 has a pre-process for producing product parts and a post-process for producing products using the parts produced by the pre-process. In order to produce a product, it is necessary to go through multiple processes. When the number of product production requests and the delivery date are determined by the sales person in charge of the product, in order to produce the product sequentially from the final process to the previous process. The required number of parts required and the delivery date are assigned.

  Then, the production plan creation device 1 can operate each process by presenting the production plan to a management terminal including a monitor or the like that can be referred to by workers in each process. As shown in FIG. 1, the production plan creation apparatus 1 has a configuration for supplying production instructions to each process. In the following description, updating of the production plan in the previous process will be described in relation to a specific previous process and subsequent process in the production process. However, the production plan creation device 1 includes all of the production processes. The same processing is performed in the steps before and after the above.

  In such a production process, basically, the number of production instructions for the previous process is calculated in response to a request for the subsequent process. However, as the number of sales varies, as a result of verifying the production capacity ahead of a certain period of time, as shown in Fig. 2, if there is a day that exceeds the production capacity limit (capacity of production) of the facility capacity limit of the previous process Then, one or more product numbers are extracted from the group of parts that need to be produced on the day exceeding the production capacity limit of the facility capacity by the calculation of the production plan creation device 1, and advanced to the date when production is possible.

  As shown in FIG. 1, the production plan creation device 1 includes a plan storage unit 11 that inputs post-process plan information S1 and pre-process instruction information S2, a master storage unit 12 that stores part configuration master information S3, and pre- and post-processes. And an inventory storage unit 13 for storing inter-inventory information S4 and reference inventory information S5. The plan storage unit 11, the master storage unit 12, the inventory storage unit 13, and the advance information storage unit 16 to be described later are configured by a storage unit such as a hard disk device.

  The post-process plan information S1 is production plan information representing a product production plan to be performed in the post-process. This post-process plan information S1 is formed by associating the production date, the product number of the product created on the production date, and the production number of the product. The post-process plan information S1 is created by the management terminal operated by the manager of the post-process and supplied to the production plan creation apparatus 1.

  The pre-process instruction information S2 is part production instruction information required for the pre-process. This pre-process instruction information S2 indicates the production date, the part number of the part created on the production date, and the number of parts produced. The pre-process instruction information S2 is created by the management terminal operated by the manager of the pre-process and supplied to the production plan creation device 1.

  The master storage unit 12 stores part configuration information indicating the correspondence between the part number information of a product produced in a subsequent process and the part number of a part produced in a previous process. In the master storage unit 12, the part number of the part produced in the previous process is supplied as the part configuration master information S3, and the part number of the product produced in the subsequent process is supplied as the part configuration master information S3. Note that the pre-process and the post-process do not necessarily correspond one-to-one, and the pre-process may also create parts of different products necessary for a plurality of post-processes.

  In addition, the production plan creation device 1 includes a component configuration development processing unit (request processing unit) 14 that identifies the correspondence between parts in the previous process and the subsequent process, and a forward determination criterion creation processing unit 15 that creates a standard for whether to advance the process. A forward information storage unit 16 for storing information related to the advance, a production instruction advance processing unit 17 for determining whether to advance parts production, and a pre-process production instruction unit 18 for outputting production instruction information to each previous process Is provided. The production instruction advance processing unit 17 and the previous process production instruction unit 18 constitute a production instruction creation unit.

  The component configuration development processing unit 14 refers to the post-process plan information S1 and the pre-process instruction information S2 stored in the plan storage unit 11, and identifies the part product number of the pre-process required for the post-process product production. Specifically, the product part number produced by the post process and the part part number necessary for producing the product are identified from the part configuration information stored in the master storage unit 12 from the post process plan information S1.

  Then, based on the number of products produced for each production date included in the post-process plan information S1, the part configuration development processing unit 14 determines the part number that needs to be produced in the previous process and the number of parts produced for each production date. The request information S6 for the preceding process specified in (5) is generated and supplied to the production instruction advance processing unit 17.

  The advance determination criterion creation processing unit 15 uses the preceding and following process inventory information S4 and reference inventory information S5 stored in the inventory storage unit 13 and the advance history information S9 supplied from the previous process production instruction unit 18 to perform the previous process. Create a standard for determining whether to move forward. The advance judgment criteria include an excessive amount of parts in the previous process, a part production date advance part in the past, the number of parts production canceled, and a part part advance part number in the past.

  Among these advance judgment criteria, the excess inventory of parts in the previous process is calculated by comparing the inventory information S4 before and after the process of each process updated as needed and the reference inventory information S5, and calculating the excess inventory. It is determined. In addition, the number of times the production of the part is canceled is counted for each part by changing the production plan in the post-process obtained by the advance determination criterion creation processing unit 15 acquiring the post-process plan information S1. In the past, the part production date advance period and the number of parts production date advance in the past are determined for each part based on the advance history information S9 for each part. The forward determination criterion created by the forward determination criterion creation processing unit 15 is accumulated in the forward information storage unit 16 as the forward determination result information S8.

  The production instruction advance processing unit 17 is output from the provisional pre-process production instruction information S7 obtained by extracting a predetermined period from the pre-process instruction information S2 stored in the plan storage unit 11 and the component configuration development processing unit 14. Request information S6 for the previous process is acquired. As the provisional pre-process production instruction information S7 and the pre-process request information S6, information for a predetermined period to be advanced, such as one week, is acquired by the production instruction advance processing unit 17.

  The production instruction advance processing unit 17 uses the current production date specified by the provisional previous process production instruction information S7, the number of productions for each product number, and the previous process request information S6 obtained from the subsequent process plan information S1. Using the specified production date, part number, and production number, it is determined whether or not the production date requested by the request information S6 for the previous process is equal to or greater than the limit production number of the predetermined maintenance capability.

  When the number of productions on the production date requested by the request information S6 for the previous process is equal to or greater than the number of productions at the predetermined maintenance capacity limit in the previous process, the production instruction advance processing unit 17 is requested. Among the part product numbers that need to be produced in the previous process on the production date, the part product number corresponding to the advance judgment criterion stored in the advance information storage unit 16 is recognized. Then, the production instruction advance processing unit 17 searches the production date obtained as a result of the search by searching for the production date that does not exceed the production number of the maintenance capacity limit even if the production number of the parts corresponding to the advance judgment criterion is advanced. Update production plan information to advance. Of course, the production date of the advance destination is searched within a range before the production date requested from the subsequent process.

  The pre-process production instruction unit 18 transmits the production instruction information S10 updated by the production instruction advance processing unit 17 to the management terminal managed by the manager of the pre-process. As a result, in the previous process, the part number designated by the production instruction information S10 can be produced in advance within the range of the production number within the predetermined maintenance capacity limit. The production instruction information S10 is stored in the plan storage unit 11 as previous process instruction information S2, for example, after being confirmed by the management terminal in the previous process.

  Further, when the production date of the part in the previous process is advanced, the pre-process production instruction unit 18 sets the part number and the number of days advanced in advance to the advance determination criterion creation processing unit 15 as the history information S9. Supply. As a result, the forward determination criterion creation processing unit 15 can create the forward determination criterion based on the forward history information S9 as described later, and can store it in the forward information storage unit 16 as the forward determination result information S8.

  For example, as shown in FIG. 2A, the production plan creation apparatus 1 configured in this way is a temporary process for the previous process over a predetermined period from 2007/09/20 to 2007/09/26. Based on the pre-process production instruction information S7 and the pre-process request information S6, a comparison is made between the number of production on each production day and the number of production at the facility capacity limit in 2007/09/20 to 2007/09/26. As a result, the production instruction advance processing unit 17 adds the production date and the number of productions requested by the request information S6 for the previous process within the period of the acquired provisional previous process production instruction information S7. 23, September 24, 2007, it is determined that the required number of production exceeds the production capacity limit of the previous process.

  In this case, the production instruction advance processing unit 17 reads out the advance determination result information S8 stored in the advance information storage unit 16 and exceeds the production capacity limit of the facility capacity of the previous process. In 24, select the part number that meets the criteria for the advancement among the part numbers that are required to be produced. As a result, the production instruction advance processing unit 17 can identify that the part number a scheduled for production on September 23, 2007 and the part number c scheduled for production on September 24, 2007 can be advanced, and the part number a, c. Search for a production date that can be advanced for each. As a result, it is assumed that the part product number a is produced in advance on 20/20/2007, and a new production instruction is created in which the product part number c is produced in advance on 21/09/2007. To the management terminal of the previous process is transmitted as production instruction information S10.

  As described above, according to the production plan creation device 1, the number of parts produced included in the request information S6 for the previous process is compared with the production possible number per production date contained in the production instruction information for the previous process. If the production number of parts included in the request information S6 for the previous process exceeds the production possible number, the production date when the production number of parts included in the request information S6 for the previous process exceeds the production possible number The production plan information can be updated by selecting a part to be produced before the production date from among the parts produced in advance, determining the production date to produce the part ahead of schedule. As a result, the production plan creation device 1 can produce parts according to the requirements of the post-process even if the requirements of the post-process vary and there is no sufficient manufacturing capability in the pre-process. Specifically, it is possible to avoid exceeding the facility capacity limit on the production date in 2007/09/20 to 2007/09/26, and it is possible to reliably create a part in accordance with the requirements of the post-process by the pre-process.

  The production instruction advance processing unit 17 selects that the part number to be advanced, but if there is no production day that can be advanced because there is no space on another production day within the predetermined period, it is determined that the production process cannot be advanced. You may notify to the management terminal or the management terminal of the post process which output the request | requirement as alarm information. As a result, it is possible to prompt the manager of the previous process or the subsequent process to review the plan of each process or increase the number of production at the facility capacity limit in each process.

  Next, if the production number exceeding the facility capacity limit of the previous process is exceeded by the request information S6 for the previous process, the production plan creation device 1 is scheduled to be produced on the production date exceeding the production number of the facility capacity limit. A processing example for selecting one of the product numbers will be described.

  The selection process of the part number to be moved forward is performed by referring to the preceding and following process inventory information S4 and the reference inventory information S5 stored in the inventory storage unit 13 by the advance determination criterion creation processing unit 15 in the past. When the stock amount becomes excessive, the excess stock amount is calculated. Then, the advance determination criterion creation processing unit 15 stores the excess inventory amount for each previous process and each part in the advance information storage unit 16 as advance determination result information S8.

  Then, as shown in FIG. 3B, the production instruction advance processing unit 17 sets the part numbers a, b, and c scheduled to be produced on the production date (September 25, 2007) exceeding the production capacity limit of the equipment capacity. When one of them needs to be selected, the excess inventory quantity for each part and for each part stored in the advance information storage unit 16 as shown in FIG. Based on this excess inventory, the production instruction advance processing unit 17 updates the production instruction so that the inventory of the part number c is the smallest, so that the part number c is given priority.

  As a result, the production plan creation device 1 can improve the cash flow by avoiding an excessive inventory amount in a business in which the product delivery date or quantity changes.

  Further, as shown in FIG. 4 (a), other selection processes for the part part number to be advanced are advanced in the past from the advance days for each part part number included in the advance history information S9 by the advance determination criterion creation processing unit 15. The information storage unit 16 stores the forwarded period of the part number that has been moved forward.

  Then, as shown in FIG. 4B, the production instruction advance processing unit 17 sets the part numbers a, b, c scheduled to be produced on the production date (September 25, 2007) exceeding the production capacity limit. When one of them needs to be selected, the advance period of the part numbers a, b, and c shown in FIG. From this advance period, the production instruction advance processing unit 17 updates the production instruction so that the part part number a is preferentially advanced because the part part number a has the shortest advance period.

  Thus, the production plan creation device 1 can reduce the inventory amount of parts as much as possible, and can improve the cash flow.

  Furthermore, as shown in FIG. 5 (a), another selection process of the part number to be advanced is a production plan in the subsequent process obtained by acquiring the subsequent process plan information S1 by the advance determination criterion creation processing unit 15. The number of cancellations obtained for each part by the change is moved forward and stored in the information storage unit 16.

  Then, as shown in FIG. 5 (b), the production instruction advance processing unit 17 sets the part numbers a, b, and c to be produced on the production date (September 25, 2007) exceeding the production capacity limit of the facility capacity. When one of them needs to be selected, the number of cancels of the part numbers a, b, and c shown in FIG. Based on the number of cancellations, the production instruction advance processing unit 17 updates the production instruction so that the part number a is prioritized because the number of cancellations of the part number a is the shortest.

  As a result, the production plan creation device 1 gives priority to parts that have a low risk of being canceled as much as possible, and preferentially produces parts that can be reliably delivered to the subsequent process, thereby reducing the risk of excess inventory. Can be reduced.

  Furthermore, as shown in FIG. 6 (a), another selection process for the part product number to be moved forward is a part that has been forwarded in the past from the part product number included in the forward history information S9 by the forward determination criterion creation processing unit 15. The number of advance of the product number is advanced and stored in the information storage unit 16.

  Then, as shown in FIG. 6 (b), the production instruction advance processing unit 17 sets the part numbers a, b, and c to be produced on the production date (September 25, 2007) exceeding the production capacity limit. When any one of them needs to be selected, the number of forward movements of the part numbers a, b, and c shown in FIG. From this advance count, the production instruction advance processing unit 17 updates the production instruction so that the part part number c is advanced in advance because the part part number c has the most advance number.

  As a result, the production plan creation device 1 can reduce the risk of excessive inventory by preferentially producing parts that are frequently advanced and are likely to be delivered to the subsequent process.

  In this way, the production plan creation device 1 can advance parts production in the previous process while reducing the risk of excessive inventory and cancellation. The production plan creation device 1 can also select another part part number using another forward judgment criterion when there is no production date to be forwarded after determining the part part number to be forwarded according to a certain forward judgment criterion. . Furthermore, the production plan creation device 1 may set the priority order for the advance judgment criterion used for selecting the part product number by an instruction from the management terminal in the previous process or the management terminal in the subsequent process.

  The above-described embodiment is an example of the present invention. For this reason, the present invention is not limited to the above-described embodiment, and various modifications can be made depending on the design and the like as long as the technical idea according to the present invention is not deviated from this embodiment. Of course, it is possible to change.

It is a block diagram which shows the structure of the production plan preparation apparatus to which this invention is applied. It is a figure explaining using the production plan creation apparatus to which the present invention is applied to advance parts that exceed the production capacity limit of the previous process, (a) production instruction before advance, (b) advance This is a later production instruction. It is a figure explaining using the production plan preparation device to which the present invention is applied to advance parts exceeding the production capacity limit of the facility capacity of the previous process, where (a) is past excess inventory, and (b) is advanced. It is a production instruction before and after. It is a figure explaining using the production plan creation apparatus to which the present invention is applied to advance parts that exceed the production capacity limit of the previous process, (a) is a past advance period, (b) is before and after the advance. It is a production instruction. It is a figure explaining using the production plan creation device to which the present invention is applied to advance parts that exceed the production capacity limit of the previous process, (a) is the number of parts cancellation, (b) is before and after the advance It is a production instruction. It is a figure explaining using the production plan creation device to which the present invention is applied to advance parts that exceed the production capacity limit of the previous process, (a) the number of previous advance, (b) before and after the advance It is a production instruction.

Explanation of symbols

DESCRIPTION OF SYMBOLS 11 Plan memory | storage part 12 Master memory | storage part 13 Inventory memory | storage part 14 Parts structure expansion | deployment process part 15 Judgment reference preparation process part 16 Information storage part 17 Process part 18 Pre-process production instruction | indication part

Claims (5)

In a production plan creation device for managing a production process having a pre-process for producing product parts and a post-process for producing a product using the parts produced by the pre-process,
Correspondence between the production plan information that represents the production plan of the product to be performed in the subsequent process, the production instruction information of the part required in the previous process, the product number information of the product produced in the subsequent process, and the part number of the part produced in the previous process A storage unit for storing component configuration information indicating
A request processing unit that specifies a part number corresponding to a part number of a product included in the production plan information based on the part configuration information, and generates request information that specifies the number of parts produced in the previous process for each production date; ,
The number of parts included in the request information generated by the request processing unit is compared with the number of producible parts for each production date of the previous process, and the number of parts included in the request information is If the number exceeds the production possible number of parts included in the request information, select the parts to be produced before the production date among the parts produced on the production date, and bring the parts forward A production plan creation device comprising: a production instruction creation unit that determines a production date for production and updates the production instruction information. The storage unit stores the excess inventory of parts in the previous process,
The production plan creation device according to claim 1, wherein the production instruction creation unit selects a part that has a small inventory excess in the past as a part to be preferentially produced. The storage unit stores an advance period of production date of parts in the past,
2. The production plan creation device according to claim 1, wherein the production instruction creation unit selects a part that has a short advance period as a part to be produced with priority. The storage unit stores the number of times production of parts is canceled,
2. The production plan creation device according to claim 1, wherein the production instruction creation unit preferentially selects a part with a small number of canceled times as a part to be brought forward and produced. The storage unit stores the number of advance parts production dates in the past,
The production plan creation device according to claim 1, wherein the production instruction creation unit preferentially selects a part that has been forwarded in the past as a part to be preferentially produced.

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