JP2009134399A - Sales production planning method, sales production planning system and computer program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily facilitate countermeasures to the fluctuation of a use schedule, and to improve planning precision by creating a sales projection plan by ordering units. <P>SOLUTION: This sales production planning method includes an input process for inputting the result order data of a product whose order has been already received and stock order data created based on the use schedule of a client as data including the delivery date, quantity, and production specifications; a process for creating sales plan data from the input result order data and stock order data; and a process for comparing the total quantity of the order of the sales plan data with the production capacity of a production capacity designated by the order in a prescribe period, and for changing at least one of data related with the delivery date and the production passage process of at least one of the result order data and the stock order data so that the total quantity of the order can be within production capacity. Each process is executed by a computer by defining the result order data and the stock order data as order units. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a sales production planning method, a sales production planning system, and a computer program for realizing the processing by a computer in a material production company that manufactures material products as commodities.

  Conventionally, a raw material production company (for example, a thin steel plate, a surface-treated steel plate, a thick steel plate, a steel strip, a shape steel, etc.) that performs a certain process on a common starting material and manufactures various raw material products from the processed raw material. In the steel industry that manufactures steel products represented by steel pipes, etc., because there are many types of products and the manufacturing period is long, products that are being manufactured or manufactured (iron sources) We have created sales plans and production plans from the perspective of how to allocate optimally. Then, when assuming a prospective order that is necessary for the creation of a sales plan or production plan but has not yet received an order, the “frame” is a large frame of the sales quantity frame and the production quantity frame, which are the estimated quantities stacked. It was done by setting the unit value. In addition, the transportation plan was created when the assortment was completed.

  As a management of this kind of steel products, for example, a method for setting delivery date and production instruction date based on customer's usage plan, appropriate stock quantity, distribution department and customer's inventory, and grouping delivery date management Has been proposed (see, for example, Patent Document 1). In addition, as an example of a work plan for steel products, it has been proposed to create a work plan in each manufacturing process by assigning a consistent lot code to organize a production lot (for example, Patent Document 2). In addition, as an example of a production plan method, a monthly production plan that maximizes the difference between the total sales price calculated from the product shipment volume, the total variation amount corresponding to the processing amount, and the total variation amount corresponding to the processing amount. Has been proposed (see, for example, Patent Document 3 and Patent Document 4).

Japanese Patent No. 2847276 JP 2002-91537 A JP 2006-309573 A JP 2006-338110 A

  In the conventional production planning method, the production plan is created by using the sales plan frame and the production plan frame as a unit, and since there is no detailed information for each order in the plan content, the sales plan and the production plan are consistent. There was no problem. For this reason, there is an inconvenience that the planning accuracy is low and a product which is not scheduled to be picked up by a customer is manufactured, resulting in an increase in defective inventory. In particular, in the case of steel, a sales plan is created by obtaining information on the planned use of steel from a major customer, but the current method has a problem that it is difficult to cope with fluctuations in the planned use. In addition, transportation plans are also created individually for products for which assortment has been completed, and are not linked to the assortment schedule information.

  In addition, in the above-mentioned Patent Document 1, it is proposed to manage the delivery date after grouping orders for each specification part, but in order to group orders, the past order results are analyzed. There is a problem that the processing is difficult. Furthermore, the method of Patent Document 1 does not disclose a sales plan / production method, but only a delivery date management method.

In addition, the method proposed in Patent Document 2 has a problem that order information must be analyzed in order to assign a consistent lot code.
In addition, the methods proposed in Patent Document 3 and Patent Document 4 have a problem that the production accuracy of the production plan is a product unit, but if the plan is created in a coarse unit including the order units, the plan accuracy does not increase. .

  Furthermore, the reason behind the continued creation of sales plans and production plans based on the amount of the “frame” mentioned above is that the amount of steel production (supply amount) exceeds the order amount (demand amount). It is the premise that it can respond. However, in recent years, the supply-demand relationship has been reversed, and the plan using the conventional “frame” is not accurate enough or cannot respond quickly to changes in the order quantity from the customer. The problems such as came out.

  On the other hand, creating sales plans and production plans in “order units” instead of “frames” has traditionally existed, but material production companies such as the steel industry have many types of products and many customers. For this reason, there are a wide variety of order data forms, and it is difficult to apply them as they are.

  The present invention has been made to solve the above-mentioned problems, and by creating a sales production plan in units of orders, it is possible to easily cope with fluctuations in the use schedule and to improve the planning accuracy. An object of the present invention is to provide a sales production planning method, a sales production planning system, and a program for causing a computer to execute the processing of the sales production planning method.

The inventors have analyzed the sales plan and production plan creation procedure and the order data format, and found the following.
1) Expected orders that will be placed in the following month are set in units of “frames” based on the usage schedule information of customers such as customers and trading companies. Has schedule information. Therefore, in the sales plan and production plan processing, if the usage schedule information of the order unit possessed by the customer is used effectively, it is an orderly and unified data format for all the consumers. (Data structure) can be processed.

2) In the order data, repeated orders (referred to as “repeat orders”) from the same consumer over a long period of time (for example, 5 years, 10 years) occupy a relatively large proportion of the orders. . In these orders, the delivery date and quantity are changed, but other items such as manufacturing specifications are not changed. Therefore, when setting a prospective order, items (manufacturing specifications, etc.) that have been confirmed other than the quantity and delivery date are prepared in a preset data format (model data) and based on the customer's use schedule It is recommended that only the quantity and delivery date be entered in order units.
And based on said knowledge, it came to the present invention shown below.

  A sales production planning method according to the present invention is a sales production planning method for creating a sales plan and a production plan in a material production company that manufactures various material products as commodities. Order data input process that inputs expected order data created based on the customer's use schedule as data including delivery date, quantity, and production specifications, and sales plan data is created from the input actual order data and expected order data The sales plan data creation step stored in the storage means and the total quantity of orders in the sales plan data in a predetermined period are compared with the production capacity of the production line specified by the order, and the total quantity of the orders In the production capacity range, at least one of the actual order data and the expected order data is a date related to a delivery date and a production passing process. A sales plan data adjustment step for adjusting the sales plan by changing at least one of the data, and each step is executed by a computer on the basis of the actual order data and the expected order data to create a sales plan .

In the sales production planning method according to the present invention, the sales plan data adjustment step further includes:
B) Production volume on production line b) Delivery rate compliance rate
Is used as a constraint condition for optimization, at least one of the data related to the delivery date and the production passing process of at least one of the actual order data and the expected order data is changed.

  The sales production planning method according to the present invention is expected by inputting the delivery date and quantity in the format data in which the production specification information excluding the delivery date and quantity is set in advance based on the use schedule of the product by the consumer. A first prospective order creation step of creating order data;

  The sales production planning method according to the present invention inputs delivery date and quantity data based on a product use schedule in a consumer, and enters the input data and production specification information of actual order data corresponding to the product. Based on this, a second prospective order creation step of creating an prospective order is provided.

  The sales production planning method according to the present invention inputs the sales plan data adjusted in the sales plan data adjustment step, and schedules the passing line of the production manufacturing process based on the sales plan data. And a production plan creation step of determining a scheduled passage date and time and creating a production plan.

  The sales production planning method according to the present invention calculates the production amount within a predetermined period by accumulating the quantity of orders for which the passing line of the manufacturing process is scheduled, and specifies the planned production amount for each order. If it is determined that the order can be produced and cannot be produced, the sales plan is adjusted in the sales plan data adjustment step.

  The sales production planning method according to the present invention creates a product transportation plan to a consumer based on the production plan and based on the delivery date of the actual order and the expected order.

  In the sales production planning method according to the present invention, when at least one of the actual order data and the expected order data is changed, the sales process and the production plan are recreated by repeating the above steps.

  A sales production planning system according to the present invention is a sales production planning system for creating a sales plan and a production plan in a material production company that manufactures various material products as commodities. Order data input means for inputting expected order data created based on the customer's use schedule as data including delivery date, quantity, and production specifications, and sales plan data is created from the input actual order data and expected order data Sales plan data creating means for storing in the storage means, capacity verification means for comparing the total quantity of orders of the sales plan data with the production capacity of the production line designated by the order in a predetermined period, Delivery date of at least one of the actual order data and the expected order data so that the total quantity of the orders falls within the manufacturing capacity range And a sales plan data adjusting means for adjusting a sales plan by changing at least one of the data of the fine manufacturing pass process, to create a sales plan by performing the process in order units in each of the units.

  In the sales production planning system according to the present invention, the sales plan data adjustment means may further include at least one of the actual order data and the expected order data, with c) the production amount of the production line and d) the delivery date compliance rate as the constraint conditions for optimization. On the other hand, at least one of the delivery date and the production passing process data is changed.

  The sales production planning system according to the present invention prompts the customer to input the delivery date and quantity based on the product use schedule by using the format data in which the production specification information excluding the delivery date and quantity is set in advance. The display includes a first prospective order creation means for creating prospective order data based on the input delivery date and quantity.

  The sales production planning system according to the present invention displays on the terminal a prompt to input a delivery date and a quantity based on a product usage schedule at a consumer, and the actual delivery order corresponding to the inputted delivery date and quantity and the product. A second prospective order creation step of creating an prospective order based on information on the manufacturing specifications of the data is provided.

  The sales production planning system according to the present invention inputs the sales plan data adjusted in the sales plan data adjustment step, and schedules the passing line of the production manufacturing process based on the sales plan data. The production plan creation means for creating a production plan by determining the scheduled passage date and time is further provided.

  A computer program according to the present invention causes a computer to execute arithmetic processing of each step of the above-described sales production planning method.

  According to the present invention, the order data structure is made the same for all customers, and in the creation of the expected order data for the repeated product order (repeat order), data other than the delivery date and quantity are determined. Using the “basic order” with a data structure of the type, enter only the quantity and delivery date, and enter only the quantity and delivery date in addition to repeat orders, and expand from the actual order data to the order unit data. Therefore, even when the use schedule of the customer is changed, it is possible to respond to the sales plan and the production plan quickly and efficiently.

  Also, based on the sales plan order information (delivery date, quantity, factory, production process production line information) and the production line capability of the factory production process specified by the order, the order quantity It is determined whether it is within the capacity range of the production line, and if it is not within the capacity range of the production line, the delivery date or the production line specified in the order is set so that the order falls within the capacity range of the production line. As a result, the production capacity of the production line is reflected in the sales plan, and the optimal sales plan and production plan are created by taking into account such indicators as production volume and delivery rate compliance rate. Sales plans and production plans can be created with high accuracy.

Embodiment 1. FIG.
Since the present invention creates a sales plan and production plan for each order, the order data structure is unified for all customers so that all items in each order can be processed and managed. To do. FIG. 3 shows an example of the configuration of the data. The order number, customer, delivery date, number, product type, standard, size, delivery destination, specification item (manufacturing process passage line, transfer code indicating whether factory transfer is possible, It consists of items including the destination factory. Generally, in order to create a sales plan and a production plan in units of several months, order data up to several months ahead is required. As shown in the conceptual diagram of FIG. 18, for example, in order to create a plan for three months including the current month, order data for the three months is required. However, it is usually a “actual order” for which the order has been confirmed until around the next month, but after that, it is expected that an order will be placed in the future, and it is a “prospective order” that has not been confirmed at this time. . Therefore, since this “expected order” is also used for creating a plan, in the present invention, a mechanism for providing detailed information similar to “actual order” in “expected order” is constructed.

  Therefore, as shown in the conceptual diagram of FIG. 17, the order form is (A) the product specifications and specifications are the same, repeated orders (“repeat order”), and (B) the product specifications and specifications. Are determined for each order, and are divided into two orders that must be specified ("non-repeat orders"). And (A) “Repetitive order” “estimated order” setting, data format (hereinafter referred to as “basic order”) in which all items such as production specifications and specifications other than “delivery date” and “quantity” are set in advance. (B) “For non-repeat orders”, “Predicted order” is set with a data format “general order” in which data of summary items such as customers and product types are set in advance. In the “order” setting, the data format (model data) to be used is distinguished by “repeat order” and “non-repeat order”.

  Specifically, FIG. 4 shows a configuration example of a basic order. In comparison with FIG. 3, the delivery date and quantity are blank. On the other hand, FIG. 16 shows a configuration example of a general order. Compared with FIG. 4, the number of items set in advance is as few as customers and varieties. In the following, in this specification, as shown in FIG. 17, both “repeat order” and “non-repeat order”, the actual order is “delivery order”, the repeat order expected order is “provisional delivery order”, and non-repeat The expected order is described as “scheduled order”. Therefore, the expected order in which the quantity and the delivery date are set by the basic order is the provisional delivery date order, and the order in which the quantity and the delivery date are set by the general order is the scheduled order. The sales production planning system of the present invention to which this classification is applied will be described below.

  FIG. 1 is a block diagram showing a configuration of a sales production planning system according to Embodiment 1 of the present invention. As shown in FIG. 1, the sales production planning system 1 includes an order receiving system 10, a prospective order generation system 20, a sales planning system 30, a capacity verification system 40, a production management system 50, and a transportation planning system 60. . The order receiving system 10 includes an order receiving processing section 11, a delivery date order database (hereinafter referred to as delivery date order DB. Other databases are also abbreviated as DB) 12, and a past performance order DB 13. Note that the delivery date order is an order that has already been received, and is data in which all information including the delivery date, quantity, production use, and product specifications is confirmed. The delivery date order data stored in the delivery date order DB 12 has a structure having items as shown in FIG. The past performance order DB 13 stores order data relating to products already manufactured and shipped. Although the data structure is the same as the delivery date order data, the delivery date order data is the target data of the sales production plan, whereas the data of the past actual order DB 13 is already shipped, so It is different in that it must not. Then, at the time when the product is shipped and is no longer the target of planning, the order receiving system 10 deletes the order data from the delivery date order DB 12 and stores it in the past performance order DB 13. In addition, both data are collectively referred to as performance order data below.

  The expected order generation system 20 includes a terminal 21, a provisional delivery date order generation unit 22, a provisional delivery date order DB 23, a terminal 25, a planned order generation unit 26, and a planned order DB 27. The provisional delivery date order generation unit 22 receives the input of “quantity” and “delivery date” of “basic order” shown in FIG. Temporary delivery date order data is created and stored in the temporary delivery date order DB 23. On the other hand, the planned order generation unit 26 receives input of “quantity” and “delivery date” of “general order” shown in FIG. Then, the actual order data related to the non-repeat order is extracted from the input data and at least one of the delivery date order DB 12 and the past actual order DB 13, and based on the data, the production specification is given, and the planned order data Is stored in the planned order DB 27.

  The provisional delivery date order data is expected order data relating to repeat orders, and is stored in the provisional delivery date order DB 23 in the data format of FIG. On the other hand, the planned order data is prospective order data relating to non-repeat orders, and is input in the data format of FIG. 16 at the terminal 25, but is converted into the data format of FIG. Stored in the order DB 27.

  Here, the terminals 21 and 25 may be installed in a trading company, for example, a customer who uses the product or a sales activity, and may input a use schedule. Since it is known and the manufacturer can enter the quantity and delivery date, the terminal 21 may be installed in a factory on the manufacturer side and input by the manufacturing manager.

  The sales plan system 30 includes a sales plan processing unit 31, a sales plan DB 32, and a terminal 33, and a target period for creating a sales plan and a production plan from the delivery date order DB 12, the provisional delivery date order DB 23, and the planned order DB 27. For example, delivery date order data, provisional delivery date order data, and planned order data from the present time to three months are extracted and integrated to create sales plan data for the period. The created sales plan data is stored in the sales plan DB 32.

  The capacity verification system 40 includes a capacity verification processing unit 41 and a monthly production capacity DB 42. The capacity verification processing unit 41 is installed in the head office that manages the factories of the entire company. The sales plan data is stored in the factory by referring to the production capacity data of each factory, manufacturing process, and manufacturing line in the monthly production capacity DB 42. Whether the production capacity is suitable is output to the sales plan processing unit 31. In the sales plan processing unit 31, when the result that the sales plan data exceeds the production capacity is input from the capacity verification processing unit 41, the sales plan is changed as necessary, for example, by changing the delivery date. The data is stored in the sales plan DB 32 again. This process is repeated until a satisfactory result is obtained in the capability verification processing unit 41. In addition, when changing the sales plan, not only the delivery date but also the optimization of production line production (maximization of production volume) and delivery date compliance rate (maximization of delivery date compliance rate) are used as indicators. Also, calculate and study sales plan optimization. If a satisfactory solution cannot be obtained by automatic calculation, the terminal 33 can be used to examine corrections by a person.

  The production management system 50 includes a production plan scheduler 51 and a production plan DB 52. The production management system 50 is installed in a factory that manufactures steel products, for example, and is applied to each production line of each factory based on a sales plan that is verified by the capability verification system 40 and determined to be appropriate. Production plan data is created and stored in the production plan DB 52. The created production plan data is given the date of manufacture (date and time of passing through each process of the production line). Note that the optimization of the production amount and the delivery date compliance rate in the capacity verification system 40 described above is for company-wide capacity verification, and it may not be possible to consider the detailed production conditions in each factory. Therefore, the result of creating the production plan by the production plan scheduler 51 is output to the sales plan processing unit 31, and the sales plan determined to be appropriate by the capacity verification system 40 does not match the production conditions of each factory and needs to be corrected. If there is, the sales plan processing unit 31 corrects it, and the corrected sales plan data is stored in the sales plan DB 32. This process is repeated until a satisfactory result is obtained in the production plan scheduler 51. As a result, the final sales plan data is confirmed and the production plan is also confirmed.

  The transportation plan system 60 includes a transportation plan processing unit 61, a transportation target order DB 62, an operation scheduled vehicle DB 63, a transportation plan DB 64, and a terminal 65. The production plan data created by the production plan scheduler 51 is transferred from the production plan DB 52. Enter and create a transport plan for steel products based on the production plan data.

  The order processing unit 11, the provisional delivery order generation unit 22, the planned order generation unit 26, the sales plan processing unit 31, the capacity verification processing unit 41, the production plan scheduler 51, and the transportation plan processing unit 61 are each for convenience of explanation. Although illustrated as independent, the whole may be realized by one or a plurality of computers. The same applies to each of the DBs 12, 23, 27, 32, 42, 52, 62, 63, and 64, and the whole of these may be realized by one or a plurality of DBs. The same applies to the terminals 21, 25, 33, and 65. When inputting a planned order from the same customer or trading company, it is not necessary to input a general order and a basic order on different terminals, but information from the same terminal. Input may be made. Further, when each of the above-described units 11, 21, 26, 31, 41, 51 is realized by a computer, the arithmetic processing is executed by a program stored in a storage device (not shown) of the computer.

FIG. 2 is a flowchart showing a process of the sales production plan creation system of FIG.
(S11) When the order processing unit 11 receives basic order order record information from an external computer, for example, via a network, the information is stored in the delivery date order DB 12. The data structure of the delivery date order DB 12 includes, for example, the items shown in FIGS. 3 and 10 described above. This data structure is an order data format that is unified and used in common for all orders regardless of differences in consumers and products in data processing in order units according to the present invention.
(S12) The provisional delivery date order generation unit 22 displays a display for prompting the terminal 21 to input the use schedule of the customer regarding the repeat order. For example, as shown in FIG. 8, a basic order input screen for prompting the input person to input the scheduled delivery date and quantity of the repeat order in the planning target period is displayed. In the input screen, as in FIG. 4, the delivery date and quantity are blank, the other items are issued, and a confirmed order is issued. To do. Using this basic order input screen, the operator operates the terminal 21 and inputs the delivery date and quantity for each order. The data is input, and the provisional delivery date order generation unit 22 generates provisional delivery date order data and stores the data in the provisional delivery date order DB 23. As for the input, for example, since the trading company grasps the information on the delivery date and quantity from the usage schedule and the stock status of the customer, the delivery date and quantity that will receive the order are set from that information. In addition, the production manager of the factory may input the information scheduled to be used from the consumer.

(S13) On the other hand, the planned order processing unit 26 displays a display for prompting the terminal 25 to input the usage schedule of the customer regarding the non-repeat orders. For example, as shown in FIG. 9, a general order input screen that prompts the operator to input the expected delivery date and quantity of the non-repeat order in the planning target period is displayed. Using this input screen, operate the terminal 25 to input the delivery date and quantity corresponding to each order (here, the detailed specifications are unknown, so the units are roughly divided by customers, product types, etc.) To do. It should be noted that non-repeat orders cannot be simply integrated with delivery date order data or provisional delivery date order data because detailed information regarding specifications and manufacturing is lacking like repeat orders. Therefore, the planned order processing unit 26 performs the conversion process so that the expected order of the non-repeat order can be handled in the data format of the delivery date order or provisional delivery date order. The delivery date order DB 12 and the past performance order DB 13 also include data of non-repeat orders received in the past, and information in which detailed specifications and detailed specifications of production are confirmed is added to the data. Therefore, the same result order data as the non-repeat order in which the customer and product type information is input is extracted from the delivery date order DB 12 and the past result order DB 13. Then, after accumulating the extracted data, calculate the breakdown ratio of the specifications and detailed manufacturing information that the actual order has, and give the detailed information of specifications and specifications to the non-repeat orders based on the ratio. And the quantity of each classified data is determined and used as scheduled order data.

For example, when 1200 tons of hot-dip galvanized steel sheet for customer P, which is a non-repeat order, is input as a general order use schedule, referring to the actual order data as shown in FIG. For customer P (3 months, 6 months, etc.), the data of the hot dip galvanized steel sheet is extracted and the extracted data is aggregated and classified by standard, size, delivery destination, manufacturing plant, and passing line The quantity ratio is calculated and 1200 tons are distributed according to the ratio. As a result, the expected order of the non-repeat order is also developed into a scheduled order having the same data format as the delivery date order and provisional delivery date order, and can be processed in the sales production planning system 1 in a unified manner. The planned order data is stored in the planned order DB 27. The data to be referred to may be only the delivery date order DB 12 or only the past performance order DB 13, or the data of both DBs may be used. Further, when referring to the data of the past performance order DB 13, periods such as the past one month, three months, half a year, one year, etc. may be divided, not all stored data. As a guideline for determining this period, a period in which the demand trend and market trend are almost the same as the plan target period (for example, the next three months) may be used. Moreover, it is good also as a period except the period when a demand trend or a market trend differs extremely.
In addition, in the above-described sales request input in S12 and S13, a selection screen of “basic order input” and “general order input” as shown in FIG. 7 can be prepared before the input screens of FIGS. For example, both inputs are possible with one terminal.

(S14) The sales plan processing unit 31 searches the delivery date order DB 12, the provisional delivery date order DB 23, and the planned order DB 27 for order data corresponding to the period (1 month, 3 months, etc.) for which a plan is to be created based on the delivery date. Then, the order details used for the sales plan, the quantity of each order, and the total quantity are obtained and stored in the sales plan DB 32.

(S15) The capacity verification processing unit 41 verifies whether the sales plan stored in the sales plan DB 32 can be manufactured (whether the sales volume is equal to or less than the production capacity). If the production is not possible, the sales plan is modified by changing the delivery date, the production line, etc., so that the production is possible. Further, in this capability verification, not only adjustment is made so that manufacture is possible, but also adjustment that optimizes manufacturing efficiency is performed. The details will be described based on the flowchart of FIG.

(S100) The capacity verification processing unit 41 reads the data from the monthly production capacity DB 42 in which the monthly capacity data of the manufacturing factory is stored, and collects the production capacity by factory and line.
(S101) The capability verification processing unit 41 reads the sales plan data (order data) stored in the sales plan DB 32.
(S102) The capability verification processing unit 41 sorts the sales plan order data by factory and line.
FIG. 5 shows an example in which the sales plan order data is distributed for each line of the factory. The order quantity of each line is ordered in a predetermined period unit (for example, monthly unit) in order to compare the quantity of the order with the production capacity. Find the total quantity.

(S103) The production capacity for each line of the factory is compared with the order of the sales plan.
FIG. 6 shows the capacity (X1, X2...) In the factory line, the total quantity (Y1, Y2...) Of orders in the sales plan of the line, and the difference (Z1, Z2...) Between the two. Determine if the difference (Zl, Z2 ...) is negative. If the difference (Zl, Z2 ...) is negative, the sales plan will not be established.
(S109) If the capability verification processing unit 41 determines that the difference (Z1, Z2,...) Is negative, the sales verification DB 41 accesses the sales plan DB 32 and sells the sales included in the factory line where the difference is negative. Read plan order data.
(S110) The capability verification processing unit 41 refers to the delivery date and passage line (or transfer code) of the read order data, and changes the order details data (delivery date, change to another passage line with a margin). Determine if it is possible. For example, the capability verification processing unit 41 may make a determination as shown in FIG.

(S201) It is determined whether the delivery date of the provisional delivery date order or the scheduled order can be changed. For example, it is determined whether or not there is an order whose set delivery date is a predetermined number of days or more ahead of the current time (that is, an order whose delivery date may be delayed because there is a low probability of actually receiving an order).
(S202) If there is an order whose delivery date can be changed, the delivery date is changed to the next month. First, changing the delivery date is given priority because the data is based on the schedule and there are uncertain factors, and it is desirable to avoid changing the manufacturing process for only a part of the orders, if possible in manufacturing and shipping management. is there.
(S203) If there is no order whose delivery date can be changed, it is determined whether or not the production passing process can be changed (factory transfer is possible).
(S204) If there is an order that can change the manufacturing passing process, the manufacturing passing process is changed.
(S205) If there is no order that can change the production passing process, the only way to change the delivery date is to change the delivery date to the next month. For example, change from a late delivery date to the next month.

  Note that delivery date changes and passing process changes may be processed automatically. However, if all of the automatic processing cannot handle them, a screen display as shown in FIG. The relationship with the sales plan may be displayed and correction processing may be performed. In the example of FIG. 11, the order data related to the line is changed by performing a ☆ mark or coloring display on the line where the order quantity exceeds the production capacity (“hot rolling” “CGL (molten zinc)”). Display a screen prompting you to Furthermore, when the cursor is moved to the line position and clicked, an order list passing through the corresponding line as shown in FIG. 12 is displayed, and sorting (sorting) by customer, delivery date, product type, etc., or specific data May be selected and displayed (filtered), or the screen may be displayed with a function that makes it easy for the examiner to determine data change.

Such a process is repeated in the process S103 of FIG. 14 until the sales plan quantity is within the range of the production capacity.
(S104) When the sales plan quantity falls within the range of the production capacity, the production quantity (a production rate that is a ratio to the maximum production capacity) is calculated for each line for the data. When calculating the production rate, the maximum production capacity may be stored in advance in a table or the like and compared with it.
(S105) Further, the delivery date achievement rate of the sales plan is calculated.
(S106) This order detail data, production rate, and delivery date achievement rate are temporarily stored.

(S107) The capability verification processing unit 41 determines whether to end the process. For example, whether or not the calculation process of the production rate / delivery date achievement rate is N times (for example, 5 times) or less is determined based on the desired production volume, production rate, delivery date achievement rate value, etc. Until the condition is reached, the sales plan correction (S102) and subsequent steps are repeated. Also in this processing, in the order detail data change processing of S110, the previous change data is stored, and the data is automatically changed so that it is replaced with data different from that (data having the next highest change priority). Change it. When the passing process is set in a plurality of factories, the passing lines are replaced or integrated into one factory.
Moreover, even if it does not change automatically, the screen as shown in FIG. 13 is displayed, and the examiner displays the production amount of each line and the ratio (production rate) to the maximum production amount. Focusing on a line that needs to be low or close to the maximum production rate, the order data corresponding to the line may be changed and input.
(S108) By repeating the above processing, the total quantity of the sales plan data calculated for each fixed period unit (one month) is within the range of the production capacity of the corresponding period (for example, one month) of the factory / line. In addition, the sales plan data in which the production amount and the delivery date compliance rate are optimized is stored again in the sales plan DB 32.

When the capability verification process (S15) in FIG. 2 is completed as described above, the process proceeds to the process (S16) in the flowchart in FIG.
(S16) The production plan scheduler 51 installed in each factory inputs from the sales plan DB 32 the sales plan data determined to be appropriate in the capacity verification. At this time, the production plan scheduler 51 of each factory extracts and inputs only data relating to the own factory from the sales plan DB 32. The production plan scheduler 51 determines the production order of each production line for each order on the basis of the delivery date (planned assortment date). And the scheduled passage date and time of each production line are determined for every order. When determining the production order of each production line for each order, for example, the production amount of the production line is maximized or the cost is determined based on the delivery date, production production process, and production capacity of the process specified in each order. In order to minimize the load, the load verification and adjustment of the production and manufacturing process are performed to calculate the scheduled date of assortment for each order. Note that the creation information itself is a general technique, and thus description thereof is omitted here. In addition, as a result of creating the production plan by the production plan scheduler 51, it is determined whether or not there is an order that cannot be produced due to the detailed conditions, and whether the production is possible or not is output to the sales plan processing unit 31 and re-executed. consider. For example, when an optimal production plan is created by the production plan scheduler 51, the order data excluded from the production target may be output to the sales plan processing unit 31 to change the sales plan data. Then, based on the changed / adjusted sales plan, the process is repeated until the production plan becomes feasible. As a result of determining that the production plan is appropriate, the sales plan is confirmed and the production plan is also confirmed. This production plan data is stored in the production plan DB 52.
As a result, the quantity of orders in the sales plan is cumulatively calculated to calculate, for example, a monthly sales amount (assortment amount), and the sales amount (assortment amount) is configured in order units. In the sales production planning system 1, the delivery date (scheduled date) of the sales plan stored in the sales plan DB 32 is displayed on the terminal 33. As a result, the worker can visually confirm the delivery date (scheduled date).

(S17) The transport plan processing unit 61 extracts transport target data from the production plan data stored in the production plan DB 52, and stores the order data in the transport target order DB 62. Then, based on the delivery date of the order information of the production plan, it is aggregated for each delivery destination and delivery date, the order for each transportation vehicle subject to transportation planning is specified, and the transportation stored in the scheduled operation vehicle DB 63 Based on the vehicle information that can be used, an order for each vehicle that is the target of the transportation plan is identified and a vehicle dispatch plan is created, and a transportation plan is created based on the vehicle dispatch plan.
In addition, in the above, when the customer's scheduled use quantity, delivery date, etc. are changed, the information of each scheduled order used in the sales plan will also be changed. In such a case, the terminal 21 and 23 are operated, the information of the corresponding scheduled order (sales plan DB32) is changed, and said arithmetic processing is repeated. As a result, the sales plan data is re-created and the delivery date (scheduled assortment date) is also changed. In addition, production plan data is also created by the production plan scheduler 51 of the factory, and the scheduled passage date and time of each production line are also changed. As a result of the processing of the production scheduler 51 of this factory, for example, when the scheduled date of assortment is late and delivery delay to the customer occurs, the estimated date of assortment in the sales plan is advanced and the scheduled date of assortment is changed to an earlier timing. can do.

  As described above, in the present embodiment, the order schedule of non-repeat orders is also converted into the same format as repeat orders based on past results, and a plan is created for each order in the form of order details data. Therefore, for example, it is easy to respond when the customer's use schedule is changed, and when the customer's use schedule is changed, the sales plan and production plan can be changed quickly. As a result, it is not necessary to produce useless products, and defective stock can be reduced. In addition, since the sales plan and production plan are created for each order, the sales and production status can be visualized for each order.

In addition, since the sales plan is highly accurate, if a production plan is created based on the sales plan and manufactured according to the production plan, it can be manufactured according to the customer's usage schedule. Production capacity can be used without waste, and defective inventory can be reduced.
In addition, since the production plan can be created with high accuracy as described above, it is not necessary to wait until the completion of assortment, and the transportation plan should be created based on the delivery date (or scheduled assortment date). It is possible to efficiently use transportation resources while considering one to two months ahead.
Furthermore, it is possible to provide the customer with a delivery date for each order, and it is effectively utilized for the product use plan on the consumer side.

It is a block diagram which shows the structure of the sales production planning system which concerns on Embodiment 1 of this invention. It is the flowchart which showed the process of the sales production plan creation system of FIG. The example of a structure of the information of a basic order receipt track record is shown. The example of a structure of the information of a basic scheduled order is shown. It shows an example of distribution of sales plan orders for each line of a factory. It shows the capacity in the factory line, the total order quantity in the sales plan, and the difference between the two. It is the figure which showed the example of the scheduled order input screen. It is the figure which showed the example of the basic order schedule input screen. It is the figure which showed the example of the general order schedule input screen. It is the figure which showed the example of performance order data. It is the figure which showed the example of the capability verification result confirmation screen. It is the figure which showed the example of the order details display screen. It is the figure which showed the example of the evaluation result confirmation screen. It is the flowchart which showed the detail of the process (S15) of FIG. It is the flowchart which showed the detail of the process (S110) of FIG. It is the figure which showed the example of the data of a general order. It is a conceptual diagram of order data (data of repeat orders and non-repeat orders). It is a conceptual diagram of the data required for a production plan.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Sales production planning system, 10 Order reception system, 11 Order reception processing part, 12 Delivery date order DB, 13 Past performance order DB, 20 Expected order generation system, 21 Terminal, 22 Temporary delivery date order generation part, 23 Temporary delivery date order DB, 25 Terminal , 26 Scheduled order generation unit, 27 Scheduled order DB, 30 Sales planning system, 31 Sales plan processing unit, 32 Sales plan DB, 33 Terminal, 40 Capacity verification system, 41 Capacity verification processing unit, 42 Monthly production capacity DB, 50 Production Management system, 51 Production plan scheduler, 52 Production plan DB, 60 Transport plan system, 61 Transport plan processing unit, 62 Transport target order DB, 63 Scheduled operation vehicle DB, 64 Transport plan DB, 65 terminal.

Claims (14)

A sales production planning method for creating a sales plan and a production plan in a material production company that manufactures various material products as products,
Order data input process for inputting the actual order data of the products already received and the expected order data created based on the customer's use schedule as data including delivery date, quantity, and production specifications;
A sales plan data creation step of creating sales plan data from the input actual order data and expected order data and storing it in a storage means;
The total order quantity of the sales plan data in a predetermined period is compared with the production capacity of the production line specified by the order, and the actual order data is set so that the total quantity of the order falls within the production capacity range. And a sales plan data adjustment process for adjusting the sales plan by changing at least one of the data related to the delivery date and the production passing process of at least one of the expected order data,
A sales production planning method, wherein each step is executed by a computer on the basis of actual order data and expected order data to create a sales plan. The sales plan data adjustment step further includes:
B) Production volume on production line b) Delivery rate compliance rate
The sales production planning method according to claim 1, wherein at least one of at least one of the actual order data and the expected order data and the data related to the delivery date and the production passing process is changed under the constraint of optimization.   The first prospective order that creates prospective order data by entering the delivery date and quantity in the format data in which the production specification information excluding the delivery date and quantity is set in advance based on the product use schedule of the customer The sales production planning method according to claim 1, further comprising a creation step.   Secondly, data on delivery date and quantity is input based on the use schedule of the product in the consumer, and a prospective order is created based on the input data and manufacturing specification information of actual order data corresponding to the product. The sales production planning method according to claim 1, further comprising a prospective order creation step.   By inputting the sales plan data adjusted in the sales plan data adjustment step and scheduling the passage lines of the production manufacturing process based on the sales plan data, the planned passage date and time of each line are determined. The sales production planning method according to claim 1, further comprising a production plan creation step of creating a production plan.   Accumulate the quantity of orders that have been scheduled for the passing line of the manufacturing process to calculate the production volume within a given period, and specify the planned production volume for each order to determine whether the order can be produced. 6. The sales production planning method according to claim 5, wherein if the production cannot be determined, the sales plan is adjusted in the sales plan data adjustment step.   The sales production planning method according to claim 5 or 6, wherein a product transportation plan to a consumer is created based on the delivery date of the actual order and the expected order based on the production plan.   The sales plan and the production plan are recreated by repeating the above process when at least one of the actual order data or the expected order data is changed. Sales production planning method. A sales production planning system for creating a sales plan and a production plan in a material production company that manufactures various material products as products,
Order data input means for inputting the actual order data of the products already received and the expected order data created based on the use schedule of the customer as data including delivery date, quantity, and production specifications;
Sales plan data creating means for creating sales plan data from the inputted actual order data and expected order data and storing it in the storage means;
Capacity verification means for comparing the total quantity of orders in the sales plan data with the manufacturing capacity of the production line specified by the orders in a predetermined period;
Sales plan data for adjusting the sales plan by changing at least one of the delivery date and the production pass process data of at least one of the actual order data and the expected order data so that the total quantity of the orders falls within the manufacturing capacity range. Adjusting means,
A sales production planning method characterized in that a processing plan is created by performing processing in units of orders in each of the means. The sales plan data adjustment means further includes:
C) Production volume of production line d) Delivery rate compliance rate
10. The sales production planning system according to claim 9, wherein at least one of the delivery date and the production passing process data of at least one of the actual order data and the expected order data is changed under the optimization constraint.   Using format data in which manufacturing specification information excluding the delivery date and quantity is set in advance, the display prompting the customer to input the delivery date and quantity based on the planned use of the product by the consumer is used as the terminal, and the inputted delivery date The sales production planning system according to claim 9, further comprising first prospective order creation means for creating forecast order data based on the quantity.   Based on the product use schedule at the consumer, the terminal prompts the terminal to input the delivery date and quantity, and based on the input delivery date and quantity and the production specification information of the actual order data corresponding to the product, The sales production planning system according to any one of claims 9 to 11, further comprising a second prospective order creation step of creating a prospective order.   By inputting the sales plan data adjusted in the sales plan data adjustment step and scheduling the passage lines of the production manufacturing process based on the sales plan data, the planned passage date and time of each line are determined. The sales production planning system according to claim 9, further comprising production plan creation means for creating a production plan.   A computer program for causing a computer to execute arithmetic processing of each step of the sales production planning method according to claim 1.

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