JP2010061260A - Physical distribution optimization support system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To optimize the space cost and the operation cost of a physical distribution for accepting a plurality of components and supplying those components to the production line of a product according to a product production plan. <P>SOLUTION: In the physical distribution optimization support system 10, a CPU 12 includes: a space cost calculation module 58 for calculating space costs by searching the arrangement space of racks in which physical processes are arranged, and component boxes are stored and the space of a between the racks; an operation cost calculation module 60 for calculating operation costs by searching all cargo work operation time as an operation time for taking in and out the respective component boxes from the racks and all traveling time as a time in which a load conveyance vehicle travels for conveying the respective component boxes; and a cost optimization module 62 for searching a relation between the space costs and operation costs and the supply frequency, and for calculating supply frequency to minimize all the costs. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a logistics optimization support system, and in particular, logistics optimization support that supports optimization of logistics until a plurality of parts are received and these parts are supplied to a product production line in accordance with a product production plan. About the system.

  In distribution centers, warehouses, or parts supply centers in factories, shelves, etc., for temporarily storing parts, products, products, etc. are provided, and when goods are received, the goods are stored in a predetermined shelf. When goods are needed, they are taken out from the shelves in which the goods are stored and delivered. Incoming goods have a relationship with suppliers, and outgoing goods have a relationship with suppliers, and goods flow through these relationships. It is necessary to efficiently manage the flow of this article.

  For example, in Patent Document 1, as an inventory layout method in a warehouse, a loading / unloading work load is given for each product number, and a percentage% for each product number is given. The number of types of the product number (for example, 9) is counted, and the number of areas in the warehouse (9 in the above example) is determined based on the number of types. It is stated that the area is arranged including that. And, in order from the area close to the doorway in the warehouse, all the product numbers are assigned in order of the ratio% to the whole, when the number of product numbers is larger than the number of areas, it is assigned in turn, then the occupied area of each area is taken out, It is stated that frequently changing product numbers can be arranged close to the entrances and exits of warehouses by sequentially changing the allocation so that the difference in occupied area of each area becomes small.

  In Patent Document 2, as a shelf arrangement design device, each article is arranged in the order of height, and the arrangement in the shelf is finished when the articles are arranged in the width direction in order from the highest frequency and arranged to a predetermined shelf width. If the total number of shelves is determined, it is disclosed to design a warehouse that arranges all the shelves including the aisle, assign shelf numbers considering the flow line, and assign the shelf addresses in order of shipping frequency. Yes.

  In Patent Document 3, as a design support device for a distribution center or the like, the processes of the target center, for example, receiving, inspection, storage, shipping, etc. are input, and quantity information relating to these processes is input, and these processes are input. Use the recommended work system list to select the corresponding work system, for example, select from fixed shelves, automatic warehouses, fluid shelves, etc., and use the logistics information etc. to calculate specifications such as the size of the selected work system. The layout of the work system is described based on these.

JP 2001-335122 A JP 2002-297723 A Japanese Patent Laid-Open No. 10-40272

  In the prior art, a layout of a warehouse or the like is examined based on a presumed product number type, shipping frequency, and quantity information. For example, in order to supply the necessary parts according to the production plan of the factory, in the temporary storage shelves of parts, both the amount of goods received and the quantity of goods discharged will vary from time to time, but the conventional technology provides sufficient shelves on the safe side. In many cases, logistics space such as warehouse scale tends to be enlarged. As the distribution space expands, the space cost increases, and the work cost for putting in and out the parts also increases. As shown in the prior art, even if the distribution space is reduced by devising efficient shelf arrangements, when parts are frequently put in and out, it may be necessary to take a fairly wide passage for them, Simple shelving arrangements are not enough.

  In this way, it is necessary to consider the space cost and the work cost for logistics until accepting multiple parts and supplying these parts to the product production line according to the product production plan. Technology is not enough.

  The object of the present invention is to enable the optimization of the space cost and the work cost for the distribution until receiving a plurality of parts and supplying these parts to the product production line in accordance with the product production plan. It is to provide an optimization support system.

  The logistics optimization support system according to the present invention accepts a plurality of parts and uses a computer to support logistics optimization until these parts are supplied to a product production line according to a product production plan. It is a support system, which includes production master information related to daily operation time, number of products produced, and production tact, production type master information relating to the number of products for each type of product produced per day, and one for each product type. Allocation list information about the number of boxes consumed for each part allocated to the production of the product, and cargo handling work for each part in which the parts box is put in and out of the parts storage shelf provided in each logistics process. A storage device that stores logistics work master information relating to the time of handling work for each box, which is the time, and the number of boxes of each part that flows through each logistics process per day based on the production plan Means for calculating the number of distribution boxes for each day, calculating the total number of distribution work days per day for placing and taking out the total number of distribution boxes for all parts per day on the shelf using the box unit handling time for each part; When supplying the number of distribution boxes at an arbitrary supply frequency per day, one day of a loading vehicle that travels between the distribution steps and conveys the number of distribution boxes for each part according to the increase in the supply frequency Based on the relationship that the total travel time increases, the total travel time calculation means for calculating the relationship between the total travel time of the loaded vehicle per day and the supply frequency, the total load handling work time per day, and the loading vehicle The work cost calculation means for calculating the relationship between the total work cost and the supply frequency using the sum of the total travel time of the day as the work cost, and supply when supplying the total number of distribution boxes at an arbitrary supply frequency per day According to the increase in frequency, the number of distribution boxes for each part and the loading vehicle for each supply cycle Based on the relationship that the frequency of travel is reduced and the shelf installation space, which is the floor installation area of each component shelf in each logistics process, and the passage space for passing a loading vehicle provided in each logistics process are reduced. The space cost calculation means for calculating the relationship between the space cost and the supply frequency in the logistics process, and the relationship between the total cost and the supply frequency, which is the sum of the work cost and the space cost, is obtained, and the supply frequency that minimizes the total cost is optimally supplied. Cost optimization means for calculating the frequency.

  Further, in the logistics optimization support system according to the present invention, the location of each logistics process according to a logistics flow set in advance for each part in the logistics area on the computer screen using a computer graphic operation application The distribution line is connected to each flow line according to the distribution flow, the flow line total value that is the sum of the lengths of each flow line is obtained, and the flow line total value is calculated while sequentially changing the position of each distribution process. Re-determine and repeat this to find the flow line that will be the target flow line total value, set the distribution process placement position, and set the supply flow line of the loading vehicle based on this placement position The storage device stores the traveling speed of the loaded vehicle as the distribution work master information, and the total traveling time calculating means divides the distance of the supply flow line by the traveling speed of the loaded vehicle and per one supply cycle. When driving The calculated, as the total running time of the day by multiplying the feed frequency of this, it is preferable to determine the relationship between the total travel time and the frequency of supply of the day.

  Further, in the distribution optimization support system according to the present invention, for each distribution process, the number of storage boxes in the distribution process is calculated based on the number of distribution boxes for each supply time of each preset part. Calculate the number of outgoing boxes from the logistics process based on the production order of the planned product type and the provision list information, and obtain the number of stock boxes that is the difference between the number of incoming boxes and the number of outgoing boxes for each supply time, Means for determining the maximum number of inventory boxes which is the maximum value of the number of inventory boxes in one day, the storage device stores information on the size and weight of one box of each part as parts list information, and the space cost calculation means comprises: It is preferable to have a means for obtaining a shelf installation space for each part in each physical distribution process based on the maximum number of inventory boxes for each distribution process of each part and the parts list information.

  In the logistics optimization support system according to the present invention, the storage device stores the number of boxes that can be carried at one time, the traveling speed, and the vehicle width of the carrying vehicle as the logistics work master information. Carrying vehicles for each supply time based on the total number of distribution boxes for each supply time, which is the total number of distribution boxes for each part set for each supply time, and the number of boxes that can be loaded at one time for the loading vehicle. Means for calculating the required number of vehicles, and the space cost calculating means obtains the number of vehicles passing through the passages provided in each physical distribution process for a combination of preset traveling courses, and passes simultaneously. It is preferable to determine the passage space for each logistics process based on the maximum number of vehicles passing and the width of the vehicle.

  Moreover, in the physical distribution optimization support system according to the present invention, the storage device further stores a supplier of each part as the parts list information, and receives each part from a plurality of suppliers. Sometimes, for each supply time, the number of arrival boxes for each supplier is set so that the total number of arrival boxes from each supplier is leveled for each supply time of a preset supply frequency. Based on the number of boxes to be leveled, the number of receiving boxes assigned to each supplier for each supply time as a result of the leveling, and the production order of the product type in the production plan, And a means for calculating the number of distribution boxes for each supply time.

  Further, in the physical distribution optimization support system according to the present invention, the storage device has a buffer that is the number of product production cycles as a buffer amount set to absorb production fluctuation during each supply time for each distribution process. Quantity master information is stored, standard inventory time for each part is obtained based on buffer quantity and production tact, and supply frequency obtained by dividing daily operating time by standard inventory time is preset. It is preferable to provide means for frequency.

  Further, in the physical distribution optimization support system according to the present invention, the storage device stores course charge parts list information that is a relationship between the running course and the parts that the running course is responsible for transportation, and supplies at least one supply time. When there are multiple production lines and multiple vehicles are required, temporarily select the course combination of each cargo vehicle that reaches each supplier through each logistics process using the course parts list information Then, using the traveling speed of the loading vehicle, obtain the total traveling time for one day of the entire loaded vehicle under the traveling course setting, and recalculate the total traveling time while sequentially changing the traveling course combination selection, It is preferable to provide means for repeating this to set a combination of travel courses that will be the target total travel time value to a preset travel course combination.

  With the above configuration, the distribution optimization support system calculates the number of distribution boxes, which is the number of boxes of each part that flows through each distribution process per day, and uses the box unit handling time of each part to make the entire day Calculate the total work handling time per day for putting the total number of distribution boxes on the product in and out of the shelf. In addition, when supplying the total number of distribution boxes at an arbitrary supply frequency per day, a load carrying vehicle for transporting the number of distribution boxes for each part by traveling between the distribution steps according to the increase in the supply frequency. Based on the relationship that the total travel time of the day increases, the relationship between the total travel time of the loaded vehicle and the supply frequency of the day is calculated. In addition, when supplying the total number of distribution boxes at an arbitrary supply frequency per day, the number of distribution boxes for each part and the traveling frequency of the carrying vehicle for each supply cycle decrease as the supply frequency increases. The space cost and supply of all logistics processes based on the relationship between the shelf installation space, which is the floor installation area of each component shelf in the logistics process, and the passage space for passing the loading vehicles provided in each logistics process. Calculate the relationship with frequency.

  Thus, looking at the relationship between each component of the cost related to physical distribution and the supply frequency, the total handling work time is a constant value if the total number of distribution boxes is determined regardless of the supply frequency. The total travel time of the day increases with increasing supply frequency, and conversely, the shelf space and the passage space decrease with increasing supply frequency. Therefore, if the relationship between the total cost of distribution and the supply frequency obtained from these is used, the supply frequency at which the total cost is minimized can be obtained, and thereby the distribution can be optimized.

  Also, in the logistics optimization support system, by using a computer graphic operation application, the flow line total value, which is the sum of the lengths of the flow lines connected according to each logistics process logistics flow, is calculated on the computer screen. A value distribution process arrangement can be obtained. Then, based on the distribution process arrangement obtained, the supply flow line of the carrying vehicle can be set, and the distance of the supply flow line is divided by the traveling speed of the carrying vehicle to obtain the traveling time per supply time. Multiplied by the supply frequency to obtain the total running time of one day. In this way, the relationship between the total running time of the day and the supply frequency can be obtained.

  Also, in the logistics optimization support system, for each logistics process, calculate the number of warehousing boxes in the logistics process and the number of shed boxes from the logistics process, respectively, and the difference between the number of warehousing boxes and the number of shed boxes The number of inventory boxes is obtained for each supply time. And the shelf installation space required to store the maximum number of inventory boxes is obtained. In this way, even if the number of incoming and outgoing boxes changes from moment to moment, the shelf installation space is calculated based on the maximum number of storage boxes, not the maximum number of storage boxes. A reasonably required size.

  In the logistics optimization support system, the required number of cargo vehicles for each supply time is calculated from the total number of distribution boxes for each part for each supply time and the number of boxes that can be loaded once. calculate. Then, for the combination of travel courses set in advance, the number of vehicles passing through the passage between the shelf installation spaces of each logistics process is determined, and the maximum number of vehicles passing and the number of vehicles passing simultaneously are determined. The passage space for each logistics process is determined based on the vehicle width. In this way, the passage space can be reasonably required.

  In addition, in the logistics optimization support system, when each part is received from a plurality of suppliers and received, the arrival is carried in from each supplier at each supply frequency set in advance. In order to equalize the total number of boxes, the number of incoming boxes is assigned to each supplier for each supply time. Then, the number of distribution boxes for each supply time of each part is calculated based on the number of arrival boxes leveled for each supply time. Therefore, the number of distribution boxes for each supply of each part can be rationalized.

  Also, in the logistics optimization support system, the standard inventory time for each part is obtained based on the buffer amount set to absorb production fluctuations during each supply time and the production tact, and one day operation A supply frequency obtained by dividing the time by the standard inventory time is set as a preset supply frequency. If the supply frequency obtained in this way is used as the reference supply frequency, and the relationship between the distribution cost and the supply frequency is determined using this supply frequency as a starting point, the relationship between the distribution cost and the supply frequency is determined within a reasonable range. be able to.

  Further, in the logistics optimization support system, when there are a plurality of production lines of supply destinations for at least one supply time and a plurality of cargo vehicles are required, temporarily select a traveling course combination of each cargo vehicle, The total travel time for one day of the entire loaded vehicle under the travel course setting is obtained, and the total travel time is obtained again while sequentially changing the travel course combination selection, and is repeated until the target total travel time value is reached. This makes it possible to rationally set the traveling course combination.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the following, we will explain the logistics of supplying parts to the vehicle production line as a logistics from accepting multiple parts and supplying these parts to the product production line according to the product production plan. It may be a logistics for a production line that creates a new product, and may be a product other than a vehicle. In the following, as the distribution process constituting the distribution flow, acceptance, order, buffer storage, and supply lane will be described, but this is an example of the description, and other distribution processes may be used. A process may be included. Further, an assembly line will be described as a production line, but this is also an example for explanation, and any line other than the assembly may be used as long as it is supplied with a plurality of parts. For example, it may be a processing line, a painting line, an inspection line, or the like.

  The number of product types, the number of product types, the number of types of parts, the time of physical distribution work, etc. described below are examples for explanation, and can be appropriately changed according to actual production and physical distribution. is there.

  Below, the same code | symbol is attached | subjected to the same element in all the drawings, and the overlapping description is abbreviate | omitted. In the description in the text, the symbols described before are used as necessary.

  FIG. 1 is a diagram illustrating a configuration of a physical distribution optimization support system 10. The logistics optimization support system 10 is a system that uses a computer that accepts a plurality of parts and supports the optimization of logistics until these parts are supplied to a product production line in accordance with a product production plan. The logistics optimization support system 10 is a simulation computer for logistics optimization that is connected to a production management device (not shown), and includes a CPU 12 that executes arithmetic processing, an input unit 14 such as a keyboard, a printer, An output unit 16 such as a display and a storage device 30 are included.

  FIG. 1 shows a layout diagram 18 as an example of output from the output unit 16. This layout diagram 18 shows an arrangement of physical distribution processes for receiving parts from a supplier at a receiving site 22 at a factory site 20 and supplying each part to an assembly line 24 as a production line in accordance with a production plan. Yes. In FIG. 1, a delivery lane, a buffer yard, a standing position, a supply lane, and an empty box collection area are shown as the distribution process 26 other than the receiving 22. In addition, a traveling course 28 of a cargo carrying vehicle for supplying parts from the supply lane to the assembly line is shown. The logistics optimization support system 10 is a computer system having a function of optimizing and outputting such a logistics layout.

  The storage device 30 stores various data used for logistics optimization support. These data can be input from the input unit 14 and stored, but connected to a production management device (not shown) via an appropriate network as described above, and the actual production line data can be obtained via the network. It is good to acquire and memorize | store. In this way, meticulous production-related data can always be stored in the storage device 30.

  The production master information 32 is information relating to the operation time of one day, the number of products produced, and the production tact. FIG. 2 shows an example of the production master information 32. In this example, the daily operation time is 7.5 hours = 27,000 seconds, the daily product production plan number is 480 units, and the production tact is 60 seconds as the production master information 32. Has been. The production tact = (daily operation time) / (daily product production plan) is calculated.

  Returning to FIG. 1, the production type master information 34 is information relating to the number of products produced per day for the number of products produced per day. FIG. 3 shows an example of the production type master information 34. In this example, there are two types of product types, type 1 and type 2, and among the 480 products produced per day indicated by the production master information 32, type 1 is produced by 100 units and type 2 is produced by 380 units. Stored as master information 34.

  Returning to FIG. 1, the distribution work master information 36 is information related to work for supplying each part to the production line. This information includes information relating to the work of placing and disposing each part on and off the parts storage shelf by the worker, and information relating to a cargo vehicle that carries each part.

  FIG. 4 shows an example of the distribution work master information 36. In this example, the work time for the parts boxes to be put in and out of the parts storage shelves by the worker is 10 seconds for all parts A, B, and C, and the traveling speed of the loading vehicle is 1 m / second. In other words, it is shown that the organization of the cargo-carrying vehicle is to pull and drive 7 carts at a time. In addition to this, although not shown in FIG. 4, for example, information such as the vehicle width of the cargo-carrying vehicle and the number of boxes that can be carried at one time can be included in the logistics work master information 36.

  Returning to FIG. 1, the buffer amount master information 38 is information relating to the number of product production cycles as a buffer amount set to absorb production fluctuation during each supply time for each distribution process.

  FIG. 5 shows an example of the buffer amount master information 38. In this example, the buffer amount is instructed for each logistics process. That is, the receiving process has an extra part for one product production cycle as a buffer amount, the buffer storage process has an extra part for four product production cycles, and the supply lane process has one product as a buffer quantity. It is stored as buffer amount master information 38 that there are extra parts for the production cycle and that there are extra parts for the four product production cycles.

  Returning to FIG. 1, the provision list information 40 is information regarding the number of consumption boxes of each part allocated for production of one product for each product type. In other words, this is information about the number of parts when there is the same part as the part configuration of each product type.

  FIG. 6 shows an example of the allocation list information 40. Here, the required number per product is shown for each part for each product type. In this example, three parts A are required for each type 1 product, and two parts A, B, and C are required for each type 2 product. It is stored as provision list information 40.

  Returning to FIG. 1, the parts list information 42 is a collection of information necessary for production and distribution for each part. This information includes the part number of the part, the type of product used, the process position to be assembled on the production line, etc., as well as information on the supplier, the size of the box used to carry the part, and the capacity of the box. The number of parts to be processed is included.

  FIG. 7 shows an example of the parts list information 42. In this example, each of part A, part B, and part C can be accommodated in one of the parts supplier, that is, the identification code of the part manufacturer, the part number that is the part identification number, and the transport box. The number of parts, the type of product used, the width of the box, the depth of the box, the height of the box, the weight of the box, and the assembly position as the supply destination of the part are shown.

  For example, part A is part number 11111111 supplied for assembly of products of type 1 and type 2 at the assembly position shown by 4J02-14-1 from a supplier having a code of 2410. It is shown that four boxes are accommodated in a 0.36 m × 0.28 m × 0.16 m box, and the weight of the box is 0.20 kg.

  Returning to FIG. 1, the course charge parts list information 44 is information on the relationship between several running courses when the cargo-carrying vehicle carries each part and the parts that each running course is responsible for carrying. Such a list is not necessary if there is only one cargo handling vehicle, but if there are multiple cargo handling vehicles, it is better to share different driving courses than to run the same driving course at the same time. There are many. In such a case, the course charge parts list information 44 is required.

  FIG. 8 shows an example of the course charge parts list information 44. In this example, it is shown that the loading vehicle traveling on the traveling course “A” is in charge of carrying the part B, and the loading vehicle traveling on the traveling course “I” is in charge of carrying the parts A and C. ing.

  Returning to FIG. 1 again, the CPU 12 creates a production plan acquisition module 50 that acquires data such as the production master information 32 and the like, and executes a production type production order from the acquired production plan. Production sequence creation module 52, supply frequency calculation module 54 for calculating the supply frequency, warehousing timing, and delivery timing of each part based on this, and supply flow line setting module for appropriately setting the flow line connecting the logistics processes 56, a space cost calculation module 58 for calculating the space cost by determining the space for arranging the physical distribution process and storing the shelf for storing the parts box, and the space for the passage between the shelves. The total load handling work time, which is the work time for putting out and placing each part box from the shelf, from the number of parts consumed boxes, and the loading truck to carry each part box The work cost calculation module 60 that calculates the work cost by calculating the total travel time that is the travel time of the vehicle, and the relationship between the supply frequency of the space cost and the work cost is determined, and the supply frequency that minimizes the total cost is determined And a cost optimization module 62.

  Such a function can be realized by software, specifically, by executing a corresponding logistics optimization support program. A part of such functions may be realized by hardware.

  The operation of the above configuration, particularly each function of the CPU 12, will be described in detail below with reference to the flowchart of FIG. 9 and the related drawings. FIG. 9 is a flowchart showing a procedure for logistics optimization support for supporting logistics optimization until a plurality of parts are received and these parts are supplied to a product production line in accordance with a product production plan. Each procedure corresponds to each processing procedure of the logistics optimization support program.

  Specifically, FIG. 9 shows a procedure for optimizing physical distribution in a new construction of a vehicle assembly factory and a layout plan that can be loaded for remodeling. First, strategy planning is performed (S10). Here, we will develop a strategy for the personnel and space that can be spent in the factory. At this time, considering regional characteristics, location conditions, etc., for example, formulating how to set the relationship between logistics work cost and space cost, layout of parts logistics in the factory, work cost target Etc. Here, the following procedure will be described on the assumption that a logistics work cost = space cost has been formulated.

  Next, a distribution flow is set (S12). The distribution flow is a distribution procedure that indicates what process is performed after the parts are received and then distributed to the production line. At the time of new construction or remodeling of an assembly factory, only the position of the assembly line that is the production line is often determined, and the factory layout plan starts from this state. Specifically, a supplier, an assembly position, etc. are acquired from the parts list information 42 of the storage device 30, and a distribution flow plan is input from the input unit 14 etc. with reference to this.

  FIG. 10 is a diagram illustrating a state of a screen in the output unit 16 when a distribution flow plan is input. Here, assembly lines 24 and 25, which are production lines, have already been arranged on the factory site 20, and this includes the acceptance 22, the other logistics processes 26, order 1, order 2, and buffer. The state where the storage place and the supply lane are not arranged is shown.

  The logistics process acceptance 22 is a process of receiving and unloading parts from a supplier such as a parts maker outside the factory when parts are delivered at a predetermined time, for example, by a truck or the like. It is a place where a process is performed. The order is a process of arranging parts placed in various orders in order so as to be easily supplied to the production line, or a place where the process is performed. The buffer storage is a process for temporarily storing parts and the like and a place where the process is performed. The supply lane is a process where a shelf for storing each part is arranged and a place where the process is performed. In the normal position and the supply lane, the parts are stored and arranged so as to be suitable for supply, so that each part is drawn out according to the production plan and supplied to the assembly lines 24 and 25 using, for example, a loading vehicle. Is done.

  Returning to FIG. 9, next, the distribution process is arranged (S14). Specifically, using a graphic operation application such as CAD (Computer Aided Design), the input physical distribution flow data is confirmed on the graphic and placed on the factory site plan.

  FIG. 11 is a diagram showing a state in which the acceptance 22 and other logistics processes 26 are arranged on the screen using CAD. In this way, the receiving 22 is arranged away from the assembly lines 24 and 25 so as to secure a space for physical distribution on the factory site 20. Further, the forward position and the supply lane are arranged near the assembly lines 24 and 25 with reference to the parts list information 42. In the example of FIG. 11, three distribution routes are arranged from the reception 22. One is a physical distribution route from the receiving 22 to the supply lane via the buffer storage, and from there to the assembly line 24. The second is a distribution route from the reception 22 through the order 1 to the assembly line 25, and the third is a distribution route from the reception 22 through the order 2 to the assembly line 25. is there.

  Returning again to FIG. 9, the cost of the logistics process plan arranged on the CAD is roughly estimated and compared with the target cost established in S10. The approximate cost can be obtained from the production plan because the approximate quantity of the parts box is known. The total number of parts boxes placed in and out of the shelf is determined from the number of parts consumed per day from the production plan. It is possible to estimate the work time for putting the box in and out of the shelf. Since this work time is related to the cargo handling work, it can be called the cargo handling work time.

  For example, if a target production plan is made at the strategy planning stage, the cargo handling work time can be estimated based on the plan. Now, assume that this cargo handling work time is estimated to be X seconds. The X seconds can be obtained regardless of the distribution process layout.

  On the other hand, according to the logistics process plan on CAD, the linear flow line distance between each logistics process can be easily obtained. This linear flow line distance is a measure of whether the distribution process is wide or narrow. If the linear flow line distance is long, the distance required to transport the parts is long, that is, the transport time is long. If the sum of the distances of the linear flow lines that connect each logistics process along the logistics flow is the total value of the flow lines, the transport time for each supply of each part is estimated using this total value of the flow lines as a guide. it can. That is, the transportation time can be obtained by adding the linear flow line distances in the three physical distribution routes in FIG. 11 to obtain the total flow line value and dividing this by the transportation speed. The number of times of supply per day is generally known from the production scale, so if the supply frequency is multiplied by the transport time, the time required for transport can be determined. Since this time is the time during which the carriage or the like is running for transportation, it can be called the running time.

  This travel time is proportional to the supply frequency because the travel time for one supply time is multiplied by the daily supply frequency. Now, assume that this travel time is estimated as Y seconds. The total daily work handling time of the day and the total travel time of the day are collectively referred to as work cost. The work cost includes a component not related to the supply frequency and a component proportional to the supply frequency. There is. Therefore, if the supply frequency is determined, an approximate work cost can be estimated. If a reference supply frequency is set when making a strategy, the approximate work cost can be estimated using the supply frequency. In the above example, assume that (X + Y) seconds is the value.

  At the time of strategy planning, since the target work cost at the reference supply frequency is determined, if the target work cost is Z seconds, the approximate cost in FIG. 11 (X + Y) seconds and this target work cost are To be compared. When (X + Y) seconds is longer than Z seconds, the cost in the plan of FIG. 11 is too high.

  Therefore, in order to approach the cost target, the distribution process layout is improved. Specifically, from the state shown in FIG. 11, that is, from the state in which the arrangement positions of the respective distribution processes are provisionally determined according to the distribution flow set in advance for each part, the respective distribution processes are connected by linear flow lines according to the distribution flow. The flow line total value, which is the sum of the lengths of each linear flow line, is obtained, and the flow line total value is obtained again while sequentially changing the position of each logistics process, and this is repeated to obtain the target flow line total value. Find the supply flow line and set each logistics process placement position.

  In the above example, if {Z− (X + Y)} seconds is divided by the conveyance speed, it can be seen how much the flow line total value should be shortened. Therefore, the layout of each logistics process is sequentially changed on the CAD, and the flow line total value is obtained again each time. Then, the arrangement of each logistics process is sequentially changed so that the total flow line value is shorter than the distance obtained by dividing {Z- (X + Y)} seconds by the conveyance speed. FIG. 12 is a diagram showing an example in which the flow line total value is improved in this way. Here, the order 1 is abolished, the two distribution routes for the assembly line 25 are routed through one order 2, and the position of the order 2 is brought closer to the reception 22. As a result, the total flow line value becomes considerably short, and the approximate work cost can be kept within the target work cost.

  FIG. 13 is a diagram showing the distance of the linear flow line in the arrangement of FIG. In this example, the total flow line value is (20 + 5 + 10 + 30 + 5 + 5) m = 75 m. FIG. 14 is a diagram summarizing the improvement of the logistics process. Here, the state before improvement is the state of FIG. 11 and the state after improvement is the state of FIG. According to the improvement, in the case of FIG. 11, the distribution flow of the part A is from the acceptance to the assembly line through the order 1, and in the case of FIG. 12, from the acceptance to the order 2. I go to the assembly line. Since the forward position 2 is the same as that used for the part C, the parts A and C are made common from the acceptance to the forward position 2, and the linear flow line can be omitted accordingly. .

  When the distribution process layout that roughly matches the target cost is determined in this way, the flow returns to FIG. 9 again, and the supply flow line for supplying parts to the assembly lines 24 and 25, which are production lines, is set. (S16). Unlike the linear flow line described above, the supply flow line is a flow line for actually transporting each component, specifically, a transport flow line for a cargo vehicle. As described above, it is the order and the supply lane that supply the components to the assembly lines 24 and 25 in order. Therefore, in the case of FIGS. 12 and 13, the transportation flow line of the cargo-carrying vehicle is between the supply lane and the assembly line 24 and between the normal position 2 and the assembly line 25.

  FIG. 15 shows how the supply flow line is set. Here, the traveling course “A” is set between the supply lane and the assembly line 24, and the traveling course “I” is set between the forward position 2 and the assembly line 25. In this way, the flow line total value, which is the sum of the distances of the linear flow lines between each logistics process, is set to the target flow line total value, and the arrangement of each logistics process is determined. The supply flow line, which is the transport flow line of the carrying vehicle, is set.

  In this way, once the basic logistics process is arranged and the transportation flow line of the cargo handling vehicle is set, the cost for each supply frequency is calculated in order to determine the optimum supply frequency for the day. The The cost is the work cost described in the distribution process arrangement, and the space cost based on the shelf arrangement space and the passage space.

  The work cost is composed of a cargo handling work time unrelated to the supply frequency and a travel time that increases as the supply frequency increases. On the other hand, the space cost tends to decrease as the supply frequency increases. In other words, as the supply frequency increases, the number of distribution boxes for each part and the traveling frequency of the loading vehicle for each supply cycle decrease, and the shelf installation space, which is the floor installation area of each component shelf in each distribution process, The passage space for passing the cargo vehicle provided in each logistics process is reduced. Based on such a relationship, the cost for each supply frequency is obtained by the following procedure.

  That is, in FIG. 9, a production plan is acquired (S18). This process is executed by the function of the production plan acquisition module 50 of the CPU 12. Specifically, the production master information 32 and the production type master information are referred to. First, a production order is created so that production of each production type is leveled (S20). This step is executed by the function of the production sequence creation module 52 of the CPU 12. According to the production type master information of FIG. 3, since 100 type 1 and 380 type 2 are produced per day, the production order is such that if one type 1 is flowed, then 3.8 type 2 is flowed next. That's fine. Actually, if one type 1 is passed, then three or four type 2s are allowed to flow, and on average, type1: type2 = 1: 3.8. This is shown in FIG. Here, according to the production master information 32, the production tact is 60 seconds = 1 minute.

  Next, with reference to the allocation list information 40, the type of assembly part corresponding to this production order and the consumption quantity thereof are grasped, and a part consumption schedule from the start of production to the end of the day is created (S22). An example of the parts consumption schedule is shown in FIG. In FIG. 17, the number of parts required, that is, the consumption quantity, is shown for every minute from time 800 to 807, that is, from 8:00 to 8:07. For example, at time 803, since it is an assembly of type 2, it can be seen from the allocation list information 40 that two parts A, B, and C are consumed.

  Returning to FIG. 9, a consumption schedule for each component box is created from the component consumption schedule with reference to the component list information 42 (S24). An example of the box consumption schedule is shown in FIG. Here, it is shown how each component box is consumed from time 800 to 804, that is, every other minute from 8:00 to 8:04. According to the parts list information 42, since all of parts A, B, and C are stored in one box, one box is consumed every time four parts are accumulated. For example, in the case of component A, as shown in FIG. 17, since a total of four were consumed at time 800 and 801, one box was consumed at time 801, then three were consumed at time 802 and two were consumed at time 803. Therefore, it is shown that one box is consumed at time 803.

  Returning to FIG. 9 again, the number of boxes consumed for each part per day is determined from this box consumption schedule (S26). The number of boxes consumed for each part can also be referred to as the number of distribution boxes since this number of boxes flows in each distribution process. FIG. 19 shows an example of the number of consumption boxes for each part per day. Here, it is shown that only 340 boxes of part A, 190 boxes of part B, and 190 boxes of part C are consumed per day.

  Returning to FIG. 9, the daily work load is calculated based on the number of boxes consumed per day (S28). Here, with reference to the distribution work master information 36, a box unit handling work is read for each part, and the value is multiplied by the number of boxes consumed per day for each part. In the example of FIG. 19, since there are a total of 720 boxes, this is multiplied by 10 seconds, and a total of 7,200 seconds is calculated as one day's cargo handling work time.

  Then, the running work amount per supply time is calculated (S30). Here, the calculation is performed based on the distance of the supply flow line set in FIG. That is, referring to the physical distribution work master information 36, since the traveling speed of the loaded vehicle is 1 m / s, the traveling time per supply time is calculated by dividing the distance of the supply flow line by this traveling speed. . For example, if the total of the supply flow lines set in FIG. 15 is 80 m, the travel time per supply cycle is calculated as 80 seconds.

  And the relationship between work cost and supply frequency is calculated | required (S32). Assuming that the supply frequency per day is n times, in the above example, work cost = (7,200 seconds + n × 80 seconds). The state of the calculation is shown in FIG. Here, the horizontal axis represents the supply frequency n, and the vertical axis represents time as a cost of money in an appropriate conversion. Here, the handling work cost 70 is a constant value regardless of the supply frequency, and the travel time cost 72 is shown to increase in proportion to the supply frequency n. The work cost 74 is given by the sum of the cargo handling work time cost 70 and the travel time cost 72. In this way, the relationship between the work cost and the supply frequency is required. Steps S28, S30, and S32 are executed by the function of the work cost calculation module 60 of the CPU 12.

  The supply frequency n can be obtained as an optimal frequency by the following cost optimization, but it is preferable to set a certain range for the processing. FIG. 20 shows the relationship between the work cost and the supply frequency n. The supply frequency n is limited by the capability of how many parts boxes can be transported by one supply. According to the distribution work master information 36, since the number of towable vehicles and the like can be known, the minimum supply frequency, that is, the Min frequency can be determined based on this number (S34).

  Returning to FIG. 9 again, using this Min frequency as a guide, a reference frequency is set in consideration of the buffer amount (S36). The method for obtaining the reference frequency is shown in FIG. That is, the buffer amount in each distribution process is acquired from the buffer amount master information 38, and the tact time is acquired from the production master information 32. From these, the inventory time for securing the buffer amount in each physical distribution process is known. For example, in order 2, 4 cycles, that is, 4 minutes is the inventory time for securing the buffer amount. Since the inventory time based on the supply frequency can be known from the Min frequency, the inventory time for securing the buffer amount can be added to the inventory time to obtain the standard inventory time. Then, the reference frequency, which is the supply frequency considering the buffer amount, can be obtained from the reference frequency = operation time / standard inventory time. This reference frequency can be used as a guide for the range of supply frequencies in subsequent calculations.

FIG. 21 shows the procedure of load leveling. This load leveling is, for example, accepted 22
, When each part is received from multiple suppliers and received, the total number of arrival boxes delivered from each supplier is equalized for each supply time with a preset supply frequency. As described above, the number of arrival boxes is assigned to each supplier for each supply time. That is, the number of boxes at each supply time of the supply frequency n is made uniform throughout the day, which is the step of leveling the boxes (S38) in FIG. The constraint condition at this time is to secure the number of consumption boxes in the box consumption schedule described in S24.

  FIG. 22 shows how the number of boxes is leveled. Here, the supply frequency is set to 36 times, but initially, it may be arbitrarily set within the range of the Min frequency and the reference frequency. As the optimization process proceeds, the optimum supply frequency is determined, and at that time, the number of boxes is leveled again. FIG. 22 shows the classification of each part, such as the classification of one box large and heavy or small and light weight, and the number of arrivals per day from an external supplier. For example, the part A is received 18 times a day, while the part E is received once a day. By using the number of arrivals for each part, the number of arrival boxes per day, and the supply frequency, the number of arrival boxes for all parts is made to be approximately equal for each supply time. In the example of FIG. 22, the number of arrival boxes is leveled to 15 boxes at each supply time.

  Returning to FIG. 9, a box supply schedule is created (S40). Since the box supply schedule is a supply schedule for each part box for each supply time of the supply frequency n, the box consumption schedule described in S24 is a constraint condition. FIG. 23 is a diagram showing the number of boxes of each part to be secured when the box consumption schedule of FIG. 18 is divided by the supply frequency α and when divided by the supply frequency β. Thus, depending on the supply frequency, the number of boxes of each component to be secured, that is, the number of supply boxes, does not change continuously but changes discontinuously in stages.

  The box supply schedule in each logistics process is created based on the number of receiving boxes leveled according to FIG. 22 and the buffer amount in each logistics process, etc. under the constraints of the box consumption schedule shown in FIG. can do. In an actual factory, a wide variety of parts are supplied and consumed. 24 and 25 show examples of actual box consumption and box supply at a certain time.

  Thus, according to the box consumption schedule and the box supply schedule, the box of each part is supplied and consumed at each supply time determined by the supply frequency. The number of inventory boxes fluctuates. This is shown in FIG. This figure shows the transition of the number of boxes of a certain part in a certain logistics process, with time on the horizontal axis and the number of incoming boxes, outgoing boxes, and inventory boxes on the vertical axis. The size and capacity of the parts box storage shelves arranged in the distribution process are set based on the number of inventory boxes.

  Returning to FIG. 9, the maximum number of inventory boxes of each part is calculated in each physical distribution process (S42). In the example of FIG. 26, the maximum number of inventory boxes = 4 boxes is obtained. And the shelf installation space in each physical distribution process is calculated based on the maximum number of inventory boxes of each part (S44).

  FIG. 27 is a diagram illustrating a procedure for calculating the shelf arrangement space. As shown here, given a length L, a width W, and a height H that are the size of a shelf, the shelf placement space is calculated from the bottom area of the shelf and the shelf base that is the number of necessary shelves. Size is required.

  The size of the shelf can be obtained by the size of the box of each component, the maximum number of stock boxes, and the arrangement method of the boxes on the shelf. An example of a method for arranging boxes on the shelf will be described below with reference to FIGS. Here, FIG. 28 and FIG. 29 are cases in which a component box is arranged on a shelf provided with a plurality of racks in a rack shape, and FIG. 30 and FIG. This is a case where stacking is performed using partition plates.

  In the case of a shelf having a shelf board, as shown in FIG. 28, the height Th per shelf and the number of steps of the shelf based on the vertical dimension Bl, the lateral dimension Bw, and the height dimension Bh of each part. Tr is specified, and the size of the entire shelf is obtained. The procedure is shown in FIG.

  That is, first, the inventory number nINV is acquired for the part #n. As nINV, the maximum number of inventory boxes described in FIG. 26 is used. Based on the height dimension Bh of the part #n box, the height Th per shelf is specified. Since Th may already be specified based on another parts box, Th and Bh are compared, and when multiple boxes can be stacked on one shelf, the number of stacks Recalculate nINV. In the example of FIG. 28, the parts box of part # 1 is shown as being stacked in one stage with respect to Th, and the parts box of part # 2 is shown as being stacked in two stages with respect to Th.

  Then, the vertical dimension B1 and the horizontal dimension Bw of the part #n box are obtained, and multiplied by the recalculated nINV to obtain an area necessary for storing the part #n box on the shelf. Calculated. If this is done for all parts and cannot be accommodated by one shelf, the shelf number Tr is increased and designated. In this way, the bottom area of the shelf necessary for storage is calculated by dividing the necessary area for the parts box of all parts by Tr. When the dimensions of a shelf are standardized, the base number of the shelf can be obtained by dividing the bottom area of the shelf necessary for storage by the bottom area per unit of the standardized shelf.

  In the case of shelves that are stacked using partition plates, as shown in FIG. 30, the stacking that is the spacing between the partition plates is based on the vertical dimension B1, horizontal dimension Bw, and height dimension Bh of each part. The height Th per stage and the stage number Tr are specified, and the size of the entire shelf is obtained. The procedure is shown in FIG.

  That is, similarly to the description in FIG. 29, the inventory number nINV is first acquired for the part #n. The maximum stock box number is used as nINV. Then, the vertical dimension Bl, the horizontal dimension Bw, and the height dimension Bh of the box of the part #n are acquired, and the volume of one box is obtained. Multiplying the volume of this one box by nINV, the load volume for the part #n is obtained. By repeating this for all parts, the total load volume of all parts is obtained.

  Then, the height Th per stack, which is the interval between the partition plates, is designated, and the component boxes are stacked so as to fall within that height. In the example of FIG. 30, a one-part stack of part # 1 and a two-part stack of part # 4 are stored in Th, and a two-part stack of part # 2 and part # 3. It is shown that a single stack of parts boxes is still housed in Th. And when it cannot be accommodated by stacking of one partition shelf, the stacking stage number Tr is increased and designated. In this manner, the bottom area of the shelf necessary for storage is calculated by dividing the volume required for the parts box of all parts by (Th × Tr). When the dimensions of a shelf are standardized, the base number of the shelf can be obtained by dividing the bottom area of the shelf necessary for storage by the bottom area per unit of the standardized shelf.

  In this way, when the shelf installation space is used in each physical distribution process, next, as shown in FIG. 9, calculation of passage space such as passage space between the shelf is performed (S46). . The passage space is first set based on the vehicle width of the loaded vehicle so that the loaded vehicle can pass through. Then, when there are several carrying vehicles, the number of carrying vehicles passing through the same passage at the same time is obtained, and the passage width corresponding to the total vehicle width of the simultaneous passage number is obtained.

  Specifically, first, from the total number of distribution boxes for each supply time, which is the total number of distribution boxes for each part for each supply time, and the number of boxes that can be loaded at one time for each cargo handling vehicle, Calculate the required number of cargo vehicles. The number of distribution boxes of each part for each supply time can be obtained from the box supply schedule in each distribution process. The number of boxes that can be loaded at one time of the loaded vehicle can be read from the distribution work master information 36.

  Then, for at least one supply time, when there are a plurality of supply production lines and a plurality of cargo vehicles are required, a combination of the traveling course of the cargo vehicles and the supply destination is set. FIG. 32 shows the procedure. In other words, the number of distribution boxes for each part for each supply time and the number of boxes that can be loaded at one time for the carrying vehicle are determined to determine the number of routes that the carrying vehicle travels, and the parts that can be assigned to each route are examined. Set the combination of driving course and supplier.

  Specifically, while using the course charge parts list information 44, the traveling course combination of each cargo vehicle that reaches each supply destination via each logistics process is temporarily selected, and the travel speed of the cargo vehicle is used to travel the vehicle. Calculate the total travel time for one day of all loaded vehicles under the course settings, recalculate the total travel time while sequentially changing the travel course combination selection, and repeat this to travel to the target total travel time value Set the course combination.

  FIG. 33 shows an example of setting a plurality of traveling courses. Here, there are three lines 1, 2 and 3 as supply destinations, and in order to carry the number of parts to be supplied to these boxes in one supply time, there are cases in which three cargo handling vehicles are required. It is shown. As shown in FIG. 33, as a cargo carrying vehicle, the entire formation in which a plurality of carriages are pulled by a vehicle on which an operator enters is one. The number of tow trucks can be set differently depending on the carrying vehicle. In this example, it is shown that three carrying vehicles are in charge of different traveling courses. In this way, when several cargo vehicles are prepared, overlapping of traveling can be prevented to some extent by setting different traveling courses.

  However, as shown in the case of FIG. 33, there are cases where a plurality of traveling courses are set in the same path, and in such a case, a plurality of cargo-handling vehicles may simultaneously travel in the same path. Yeah. FIG. 34 shows the procedure for setting the passage layout in such a case. That is, when the combination of the traveling course and the supply destination is set, the passing timing of each cargo carrying vehicle is calculated for each passage. Then, the number of carrying vehicles that simultaneously pass through the same passage is obtained, and the width of the passage is set using the vehicle width of the carrying vehicle.

FIG. 35 is a diagram schematically illustrating how the passage width is set. Here, the position of a certain time of four cargo vehicles is shown. In this case, the width W _{2 of} the passage through which the two carrying vehicles pass simultaneously is set wider than the width W ₁ of the other passages. In this way, a passage space provided for each logistics process is set.

  When the shelf arrangement space and the passage space in each physical distribution process are set, the space in all the physical distribution processes can be obtained, and the entire space is converted into a cost to be a space cost. Then, as shown in FIG. 9, the relationship between the space cost and the supply frequency is obtained (S48). As described above, the shelf placement space is calculated by the maximum number of inventory boxes in each logistics process, and the aisle space is calculated by setting the traveling course of the cargo handling vehicle at each supply time. It is. Steps S44, S46, and S48 are executed by the function of the space cost calculation module 58 of the CPU 12.

  Therefore, between the space cost and the supply frequency, as the supply frequency increases, the number of distribution boxes for each part and the traveling frequency of the loading vehicle per supply cycle decrease, and each part in each logistics process decreases. There is a relationship in which the shelf installation space, which is the floor installation area of the shelf, and the passage space for passing the cargo vehicles provided in each logistics process are reduced. For example, if the supply frequency is once a day, each part box for one day is supplied once, so that both the shelf installation space and the passage space are large, and the space cost is high. When the supply frequency is set to n times, the number of circulation of each component box is reduced to approximately 1 / n, so that the space cost is reduced to a value close to 1 / n compared to the one with the supply frequency of one time. That is, the space cost decreases in a relationship that is almost inversely proportional to the increase in the supply frequency n.

FIG. 36 is a diagram showing the relationship between the space cost and the supply frequency together with the relationship between the work cost 74 and the supply frequency already described in FIG. As in FIG. 20, the horizontal axis indicates the supply frequency and the vertical axis indicates the cost. The work cost 74, the space cost 76, and the total cost 78 related to physical distribution are shown. As shown in FIG. 36, the work cost 74 increases linearly as the supply frequency increases, while the space cost 76 decreases in a relationship that is almost inversely proportional to the increase in supply frequency. The total cost 78 is minimized at a certain supply frequency. FIG. 36 shows that the cost becomes the minimum cost C ₀ at the supply frequency n ₀ . In this supply frequency n ₀ , work cost = space cost. The supply frequency n _S in FIG. 36 is a frequency that is initially used as a guide, for example, the reference frequency described in S36.

Thus, based on the relationship between the total cost and the supply frequency shown in FIG. 36, the optimum supply frequency is obtained as shown in FIG. 9 (S50). This process is executed by the function of the cost optimization module 62 of the CPU 12. Here, each distribution space corresponding to the optimum supply frequency n ₀ is displayed again on the CAD screen, and if necessary, the shelf layout etc. is appropriately arranged so that the supply flow lines do not overlap or intersect on the screen. Move to. Also, when the spaces overlap, for example, graphic changes are performed on the screen to obtain an appropriate layout (S52).

It is a figure which shows the structure of the physical distribution optimization assistance system of embodiment which concerns on this invention. It is a figure which shows the example of the production master information in embodiment which concerns on this invention. It is a figure which shows the example of the production classification master information in embodiment which concerns on this invention. It is a figure which shows the example of the distribution work master information in embodiment which concerns on this invention. It is a figure which shows the example of the buffer amount master information in embodiment which concerns on this invention. It is a figure which shows the example of the allocation list information in embodiment which concerns on this invention. It is a figure which shows the example of the components list information in embodiment which concerns on this invention. It is a figure which shows the example of the course charge parts list information in embodiment which concerns on this invention. It is a flowchart which shows the procedure of the physical distribution optimization support in embodiment which concerns on this invention. In embodiment which concerns on this invention, it is a figure which shows the mode of the screen in an output part when a physical distribution flow plan is input. In embodiment which concerns on this invention, it is a figure which shows a mode that acceptance and the other physical distribution process were arrange | positioned on the screen using CAD. In embodiment which concerns on this invention, it is a figure which shows the example which improved the flow line total value. It is a figure which shows the distance of the linear flow line in arrangement | positioning of FIG. It is the figure which put together the improvement of the physical distribution process in embodiment which concerns on this invention. In embodiment which concerns on this invention, it is a figure which shows the mode of a supply flow line setting. In embodiment concerning this invention, it is a figure which shows the example of the produced production order. In embodiment concerning this invention, it is a figure which shows an example of a components consumption schedule. In embodiment concerning this invention, it is a figure which shows the example of a box consumption schedule. In embodiment which concerns on this invention, it is a figure which shows the example of the number of consumption boxes for every component of the day. In embodiment which concerns on this invention, it is a figure which shows the relationship between work cost and supply frequency. In embodiment which concerns on this invention, it is a figure explaining how to obtain | require reference | standard frequency. In embodiment which concerns on this invention, it is a figure which shows the mode of box number leveling. It is a figure which shows the mode of the number of boxes of each component which should be ensured when the box consumption schedule of FIG. 18 is divided | segmented by the supply frequency (alpha) and divided by the supply frequency (beta). In embodiment concerning this invention, it is a figure which shows the example of actual box consumption. In embodiment which concerns on this invention, it is a figure which shows the example of actual box supply. In embodiment which concerns on this invention, it is a figure explaining transition of the number of warehouse boxes, the number of warehouse boxes, and the number of inventory boxes. In embodiment which concerns on this invention, it is a figure which shows the procedure of calculation of shelf arrangement | positioning space. In embodiment which concerns on this invention, it is a figure which shows a mode that a component box is arrange | positioned on the shelf by which the some shelf board is provided in rack shape. In embodiment which concerns on this invention, it is a figure explaining the procedure which arrange | positions a component box on the shelf in which the some shelf board is provided in rack shape. In embodiment which concerns on this invention, it is a figure which shows a mode that stacking is carried out using a pallet-shaped partition plate, without using a shelf board. In embodiment which concerns on this invention, it is a figure explaining the procedure which stacks and stacks using a pallet-shaped partition plate, without using a shelf board. In embodiment which concerns on this invention, it is a figure explaining the procedure which sets the combination of the driving course of a cargo handling vehicle, and a supply destination. In embodiment which concerns on this invention, it is a figure which shows the mode of an example of the setting of a some traveling course. In embodiment which concerns on this invention, it is a figure which shows the procedure of a channel | path layout setting when a plurality of cargo vehicles drive the same channel | path simultaneously. In embodiment concerning this invention, it is a figure which illustrates typically the mode of passage width setting. In embodiment which concerns on this invention, it is a figure which shows the relationship between space cost and supply frequency, the relationship between work cost 74 and supply frequency, and the relationship between all costs and supply frequency.

Explanation of symbols

  10 logistics optimization support system, 12 CPU, 14 input unit, 16 output unit, 18 layout diagram, 20 factory site, 22 acceptance, 24, 25 assembly line, 26 logistics process, 28 traveling course, 30 storage device, 32 production Master information, 34 Production type master information, 36 Logistics work master information, 38 Buffer amount master information, 40 Allocation list information, 42 Parts list information, 44 Course charge parts list information, 50 Production plan etc. acquisition module, 52 Production order creation module , 54 Supply frequency calculation module, 56 Supply flow line setting module, 58 Space cost calculation module, 60 Work cost calculation module, 62 Cost optimization module, 70 Cargo work time cost, 72 Travel time cost, 74 Work cost, 76 Space Cost, 78 Total cost.

Claims (7)

A logistics optimization support system using a computer that accepts multiple parts and supports the optimization of logistics until these parts are supplied to the product production line according to the product production plan,
Production master information on daily operating hours, number of products produced, and production tact, production type master information on number of products for each product type, and production of one product for each product type Allocation list information on the number of boxes consumed for each part, and for each part, the handling unit for each box is the handling work time per box in which the parts box is put in and out of the parts storage shelf provided in each logistics process. A storage device for storing logistics work master information relating to work time;
Based on the production plan, calculate the number of distribution boxes, which is the number of boxes for each part that flows through each logistics process per day, and use the box unit handling time for each part to determine the total number of distribution boxes for all parts per day. Means for calculating the total work hours of loading and unloading on the shelf in one day,
When supplying the total number of distribution boxes at an arbitrary supply frequency per day, according to the increase in the supply frequency, one of the cargo vehicles for traveling between the distribution processes and conveying the number of distribution boxes of each part A total travel time calculating means for calculating a relationship between a total travel time of a loaded vehicle and a supply frequency based on a relationship in which the total travel time of the day increases;
A work cost calculation means for calculating a relationship between the total work cost and the supply frequency, using the sum of the total work time of the day and the total travel time of the loading vehicle as a work cost;
When supplying the total number of distribution boxes at an arbitrary supply frequency per day, according to the increase in the supply frequency, the number of distribution boxes for each part and the traveling frequency of the cargo-carrying vehicle for each supply cycle are reduced. The space cost and supply frequency for all logistics processes are based on the relationship between the shelf installation space, which is the floor installation area of each part shelf, and the passage space for passing the cargo vehicles provided in each logistics process. Space cost calculation means for calculating the relationship between
A cost optimization means for calculating a supply frequency at which the total cost is minimized as an optimal supply frequency by obtaining a relationship between the total cost including the work cost and the space cost and the supply frequency;
A logistics optimization support system characterized by comprising: In the logistics optimization support system according to claim 1,
Using the computer graphic operation application, on the computer screen, the location of each logistics process is provisionally determined according to the logistics flow preset for each part in the logistics area, and each logistics process is moved according to the logistics flow. Connect the lines to obtain the total flow value that is the sum of the length of each flow line, recalculate the flow line total value while sequentially changing the location of each logistics process, and repeat this to obtain the target flow line total value It is provided with a supply flow line setting means for setting each logistics process arrangement position in search of a flow line to be set, and setting a supply flow line for the cargo-carrying vehicle based on this arrangement position,
The storage device stores the traveling speed of the loaded vehicle as logistics work master information,
The total travel time calculation means obtains the travel time per supply time by dividing the distance of the supply flow line by the traveling speed of the vehicle and multiplying this by the supply frequency to obtain the total travel time of the day. Logistics optimization support system characterized by finding the relationship between total travel time and supply frequency. In the logistics optimization support system according to claim 1,
For each logistics process, calculate the number of warehousing boxes for each logistics process based on the preset number of distribution boxes for each part supply, and use the production order and provision list information for each product type in the production plan. Based on the distribution process, the number of outgoing boxes is calculated, and the number of stock boxes, which is the difference between the number of incoming boxes and the number of outgoing boxes, is calculated for each supply time. With a means to determine the number of boxes,
The storage device stores information on the size and weight of one box of each part as part list information,
Space cost calculation means
A distribution optimization support system comprising means for obtaining a shelf installation space for each part in each distribution process based on the maximum number of inventory boxes for each distribution process of each part and parts list information. In the logistics optimization support system according to claim 1,
The storage device stores, as the distribution work master information, the number of boxes that can be carried at one time of the carrying vehicle, the traveling speed, and the vehicle width of the carrying vehicle,
Carrying for each supply time based on the total number of distribution boxes for each supply time and the number of boxes that can be loaded at one time of the loading vehicle, totaling the number of distribution boxes for each part for each supply time set in advance. Means for calculating the required number of vehicles,
Space cost calculation means
For a combination of driving courses set in advance, find the number of vehicles passing through the passages provided in each logistics process at the same time, and determine the maximum number of vehicles passing and the vehicle width of the vehicles that are passing simultaneously. Based on this, the logistics optimization support system is characterized by finding the passage space of each logistics process. In the logistics optimization support system according to claim 3,
The storage device further stores the supplier of each part as part list information,
When parts are received from multiple suppliers and received, the total number of incoming boxes from each supplier is leveled for each supply cycle with a preset supply frequency. And a box leveling means for assigning the number of boxes for each supplier for each supply time,
Based on the number of arrival boxes assigned to each supplier for each supply time as a result of leveling and the production order of the product type in the production plan, the number of distribution boxes for each supply time of each part is calculated. Means for calculating;
A logistics optimization support system characterized by comprising: In the logistics optimization support system according to claim 5,
The storage device
For each distribution process, store buffer amount master information, which is the number of product production cycles as a buffer amount set to absorb production fluctuations during each supply time,
A standard inventory time for each part is obtained based on the buffer amount and the production tact, and a supply frequency obtained by dividing the daily operation time by the standard inventory time is provided as a preset supply frequency. Logistics optimization support system characterized by In the logistics optimization support system according to claim 4,
The storage device stores course charge parts list information that is a relationship between the running course and the parts that the running course is responsible for carrying,
When there are multiple production lines for supply destinations for at least one supply cycle and multiple vehicles are required for transportation, each cargo delivery to each supply destination via each logistics process using the course charge parts list information Temporarily select the driving course combination of the vehicle, use the driving speed of the loading vehicle to obtain the total driving time for one day of all the loaded vehicles under the setting of the driving course, and sequentially change the driving course combination selection A logistics optimization support system comprising means for re-determining the total travel time and repeating this to make a combination of travel courses that achieve the target total travel time value to be a preset combination of travel courses.

Images