JP2014002428A - Production plan adjusting apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production plan adjusting apparatus capable of easily creating a production plan even if product stock/material stock is not sufficient, in which the time necessary for completing a product is the shortest.SOLUTION: The production plan adjusting apparatus performs computer-processing on a production plan which is created based on parts stock information 136 by using missing-part occurrence timing representing the frequency of missing-part occurrence and on what model and on which stage the missing-part occurs as parameters while considering parts delivery schedule information 137 and automatically selects a production plan or the like in which the time to complete all products is shortest. Thus, a production plan in which the time necessary to complete products is shortest even when product stock/material stock is not sufficient can be easily created.

Description

  The present invention relates to a production plan adjustment device that adjusts a production plan of a product based on an inventory amount of a material necessary for production and a delivery schedule.

  Normally, the material ordering system in factories takes into account the delivery lead time from the time the material is ordered until it is delivered, and orders the material necessary for production from the material manufacturer to the material lead time one day before the delivery lead time. It is over.

  Further, in the conventional ordering methods, the ordering frequency is set once a week, the ordering range is one week, and the delivery date is set once a week. In addition, the delivery date was set to allow more than two days to the production date.

  For example, when the delivery lead time is two weeks, it is necessary to order materials necessary for production two weeks before production. In the case of a process that operates seven days a week, the materials required for production for one week from Monday to Sunday of a week are often ordered on Fridays two and three days before, and Fridays two weeks after the order is placed. Are delivered together. Since material preparation is usually performed on the day before the start of production, material preparation is performed on Sundays for production on Monday. For example, the materials that are lacking before being delivered together on Fridays are mostly cleared on Saturdays, and there is often no material shortage. Even if there were a shortage of materials due to delays in delivery of several materials, there were many plans that met the necessary materials for batch delivery, and adjustment of the production plan was easy.

  In recent years, due to efforts to reduce inventory to improve corporate balance sheets, the ordering method is set once a week, the ordering range is one week, and the delivery date is set according to the production schedule. It has become. As a result, the material necessary for production is delivered daily for the next day, the day before the start of production. However, due to diversification of customer requests, actual production schedules often change while materials are delivered from the time of order placement, increasing the number of materials required for actual production at the stage of production preparation. doing. In addition, since the materials necessary for the production of products are delivered immediately before production, most of the plans are short of materials when the planner prepares and reviews daily production plans. There is a need for a mechanism that adjusts the production plan in consideration of the inventory of necessary materials and the delivery status.

Under such circumstances, there has been proposed a production plan adjustment system that adjusts a product production plan in consideration of an inventory amount of materials necessary for production (see, for example, Patent Document 1).
The conventional production plan adjustment system according to Patent Document 1 follows the replenishment of product stock. The stock replenishment of product stock is a method of grasping the stock in the finished product warehouse and preferentially producing the product with the earliest predicted out-of-stock date in the finished product warehouse based on an order from the customer. At this time, the production plan of the above-mentioned patent document is created by reducing the number of products that have the latest estimated out-of-stock date out of the products that use the missing material by an arbitrary percentage, and the production process capability. To see if they can make production plans.

  FIG. 14 shows processing steps of the production plan adjustment system described in Patent Document 1. In FIG. 14, step S201 confirms the product requested by the customer and its quantity. In step S202, materials necessary for producing each product are obtained. In step S203, the usage amount of each material necessary for producing each product is obtained. In step S204, the usage amount and the stock amount of each material are compared, and if at least one material is insufficient, the process proceeds to step S205. If there is no shortage, the production plan is determined in step S209 and the process is terminated. In step S205, the material having the largest deficiency is selected from the above deficient materials. In step S206, each product that uses the material with the largest amount of deficiency is obtained. In step S207, the product with the latest predicted out-of-stock date is selected from the products using the shortage material, and the production plan amount of this product is reduced by 30%. In S208, the production plan is recreated in a state where the production plan amount of the product is reduced, and step S203 is performed again. This series of processes is repeated, thereby creating a production plan that does not run out of any of the raw materials. Moreover, since the production plan amount is reduced only for the product with the latest predicted out-of-stock date, that is, the product that is most unlikely to be out of stock, it is difficult for the product to be out of stock when viewed as a whole.

JP 2003-308112 A

  In the above-described conventional production plan adjustment system, the production plan can be adjusted so that a shortage of products is unlikely to occur in consideration of the stock amount of materials. However, it is possible to reduce the product inventory / materials inventory by giving priority to products that have sufficient product inventory with respect to orders from customers. There is a problem that the production plan cannot be made.

  In addition, we compare the inventory of delivered materials with the required number of production, adjust the production plan based on the missing materials and the quantity of missing items, and have already arranged the materials for which the next delivery date and time is known. And if you make a sudden arrangement, you can't use the information on the material even if you know when it can be delivered.

  As a result, the production plan is adjusted based only on information on the delivered material inventory, so the number of products that are out of stock is unnecessarily increased in the calculation. There has been a problem that a production plan that can minimize the time required for completion cannot be created.

  The production plan adjustment apparatus of the present invention solves the above-mentioned conventional problems, and easily performs a production plan that minimizes the time required to complete a product even when there is not enough product inventory / material inventory. With the goal.

In order to achieve the above object, a production plan adjusting apparatus of the present invention comprises an input circuit, a shortage calculation / plan determination circuit, and a storage device, and the storage device contains information relating to the production of products including an initial production plan. A certain production plan information, a configuration information master in which configuration information related to materials necessary for each model that produces the product is registered, and switching time information related to the time required when switching the model in the production process are registered. A switching time information master, inventory information related to stock of delivered materials, delivery schedule information related to materials that have already been arranged and undelivered materials, and a material information master that contains material information related to lead times when arranging for each material , Startable / continuous production time information that is information on the continuous production possible time and the number of units produced for each model calculated from the material shortage state, and the initial production Production plan review information that is a production plan that has been reviewed and evaluation result information that is an evaluation result of the revised production plan are stored, and the input circuit includes the material information master, the configuration information master, and the switching time. The information master, the production plan information, the inventory information, and the delivery schedule information are input to the storage device, and the stockout calculation / plan determination circuit is configured to output the production plan information, the configuration information, the inventory information, and the delivery schedule. Information and the material information master can be used to calculate the startable / continuous production time information, and to produce all products using the number of missing parts and the occurrence timing of missing parts during production as parameters. Calculate the time required to create multiple adjusted production plans, select the revised production plan that takes the shortest time to produce all the products Characterized in that creating and updating the said from embarking possible - continuous production time information and the switching time information master and the production plan review information evaluation result information.
Further, the production plan may be adjusted by giving priority to the model with the longest continuous production time based on the information on the startable / continuous production time.

  In addition, based on the information on availability and continuous production time, even if the production process stops due to a shortage, even if the production plan is adjusted with priority given to production after materials are delivered without switching the model good.

  As described above, by using this production plan adjustment device, the production schedule created based on the inventory information of parts takes into account the delivery schedule information of parts, and the number of missing parts and which model of which parts are missing. Since it is possible to automatically select a production plan that minimizes the time required for completion of all products by computer processing using the defect occurrence timing as a parameter in the process, there is no margin in product inventory and material inventory Even in this case, it is possible to easily carry out a production plan that minimizes the time required to complete a product.

The figure which shows the structure of the production plan adjustment apparatus in embodiment The figure which shows the data structure of the material information managed by the material information master database in embodiment The figure which shows the data structure of the structure information managed by the structure information master database in embodiment The figure which shows the data structure of the switching time information managed by the switching time information master database in embodiment The figure which shows the data structure of the production tact information managed by the production tact information master database in embodiment The figure which shows the data structure of the production plan information managed by the production plan information database in embodiment The figure which shows the data structure of the inventory information managed by the inventory information database in embodiment The figure which shows the data structure of the delivery schedule information managed by the delivery schedule information database in embodiment The figure which shows the data structure of the start possible and continuous production time information managed in the start possible and continuous production time information database in embodiment The figure which shows the data structure of the production plan review information managed by the production plan review information database in embodiment The figure which shows the data structure of the evaluation result information managed by the evaluation result information database in embodiment The figure which shows the whole process outline performed with the production plan adjustment apparatus in embodiment The figure which shows the process of the stockout calculation and plan determination performed with the production plan adjustment apparatus in embodiment The figure which shows the step of the production plan adjustment system of patent document 1

  The production plan adjustment apparatus of the present invention comprises a central processing unit having an input circuit and a shortage calculation / plan determination circuit, and a storage device for storing various types of information. To adjust. In the production plan adjusting apparatus of the present invention, first, an initial production plan is recorded in a storage device. Then, the production plan is automatically changed to a production plan that has been appropriately reviewed by the shortage calculation / plan decision circuit. The out-of-stock calculation / plan decision circuit automatically and appropriately revises production plans based on various information such as production quantities and parts used, as well as stock information on product materials and delivery schedule information such as the time required to obtain them. Create When creating a production plan, create multiple adjusted production plans so that the continuous production time of any model is the longest, or create multiple adjusted production plans so that the number of model switching times is minimized. It is possible to create a plurality of adjusted production plans based on arbitrary criteria such as creating. When creating multiple adjusted production plans, the missing item calculation / plan decision circuit sequentially uses the number of missing items and the missing item generation timing at which in the production process the missing items occur as parameters. Create multiple adjusted production plans while changing. Then, a production plan adjusted by an arbitrary standard is selected from the plurality of adjusted production plans, and stored as a production plan used for production. As an arbitrary standard, an adjusted production plan that minimizes the time required to complete all products is selected.

  In this way, for the production plan created from the inventory information of parts, considering the delivery schedule information of the parts, the number of times that the shortage occurs and the defect occurrence timing of which model in which process the shortage occurs are used as parameters. Because it is possible to automatically select a production plan that minimizes the time until all products are completed by computer processing, even if there is no room in product inventory or material inventory, it is necessary to complete the product easily. It is possible to carry out a production plan that requires a short time.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a block diagram showing an embodiment of a production plan adjusting apparatus according to the present invention.
As shown in FIG. 1, the production plan adjusting apparatus of the present embodiment includes a central processing unit 1, a storage device 2, an input device 3, and a display device 4 that are made up of computers.

  In the above configuration, the storage device 2 for storing data necessary for production plan adjustment, the input device 3 for inputting various information masters, production plan information, inventory information, etc., and the created production plan are displayed. Each of the display devices 4 is connected to the central processing unit 1. The input device 3 is, for example, a keyboard, and the display device 4 is, for example, a display. The central processing unit 1 includes a master input circuit 101, a production plan input circuit 102, an inventory input circuit 103, and a stockout calculation / plan determination circuit 104.

  In response to the input of external information such as production plan information, the central processing unit 1 revises the production plan by comprehensively considering instructions for storage to each master and various information. Details of each component will be described later.

  The storage device 2 includes a material information master 131, a configuration information master 132, a switching time information master 133, a production tact information master 134, a production plan information 135, an inventory information 136, a delivery schedule information 137, a startable / continuous production time information 138, Production plan review information 139 and evaluation result information 140 are included. Details of each component will be described later.

Hereinafter, each configuration will be described in detail.
In the central processing unit 1 shown in FIG. 1, reference numeral 101 denotes a master input circuit. The master input circuit 101 registers material information, configuration information, switching time information, and production tact information in the material information master 131, configuration information master 132, switching time information master 133, and production tact information master 134 of the storage device 2, respectively. . For example, the master input circuit 101 displays an input screen on a display, and an operator inputs information from a keyboard or the like while looking at the input screen. The master input circuit 101 transfers the input information to each information master of the storage device 2. Remember. Alternatively, the master input circuit 101 can also read each information from another device and store it in the storage device 2.

  In FIG. 1, reference numeral 102 denotes a production plan input circuit, which registers production plan information input from an input device by an operator in the production plan information 135 of the storage device 2. For example, the production plan input circuit 102 checks necessary information of the production plan converted to a text file input by the input device 3 and stores it in the production plan information 135 of the storage device 2 which is a database. The production plan information registered in the production plan information 135 is an initial production plan, and is production plan information that does not take inventory into consideration.

  In FIG. 1, reference numeral 103 denotes an inventory input circuit. For example, an operator inputs a part number, a remaining number, and the like of a material newly received in a warehouse through a computer screen, and enters the inventory information 136 of the storage device 2. Remember. In addition, for the materials that have already been arranged and are scheduled to be delivered, for example, the operator inputs the part number, the planned quantity of goods storage, the planned date of goods storage, etc. via the computer screen, and stores them in the delivery schedule information 137 of the storage device 2. These can also read each information from other devices and store them in the storage device 2.

  In FIG. 1, reference numeral 104 denotes a stockout calculation / plan determination circuit. The computer performs stockout calculation based on the production plan and inventory information, determines the production plan, and the production plan review information 139 in the storage device 2. To remember. For production plan information that does not consider inventory, materials that have already been arranged and the next delivery date and time are known, and materials that can be delivered when suddenly arranged from now on. In consideration of the above, adjustment of the production plan that predicts the elimination of the shortage according to the production progress is performed by this shortage plan / plan determination means 104. Details of the processing will be described later in the processing of the shortage calculation / plan determination circuit of FIG.

  In FIG. 1, reference numeral 2 denotes a storage device. The storage device 2 includes a material information master 131, a configuration information master 132, a switching time information master 133, a production tact information master 134, a production plan information 135, an inventory information 136, a delivery schedule information 137, a startable / continuous production time information 138, Production plan review information 139 and evaluation result information 140 are stored, and description of each information will be described later with reference to FIGS.

FIG. 2 is a diagram illustrating a data structure of material information managed by the material information master 131 according to the embodiment.
2 shows an example of information in the material information master 131 stored in the storage device 2 shown in FIG.

  The material information master 131 is input from, for example, an operator or another computer system via the master input circuit 101. The material information master 131 is information that is the basis of stockout calculation / plan determination and is invariant information. The material information is information related to the material necessary to produce the product, and the material information master 131 stores the part number, part name, shelf number, number of packages, manufacturer, sudden arrangement lead time, etc. The information is stored for each part number. The part number is a number unique to the part and is a designation. The part name is a name that can identify the type of the part. The storage bin is information indicating a place in the warehouse. The number of packings is the number of parts when newly purchased. The manufacturer is the company name of the manufacturer. The sudden arrangement lead time is the time (unit: minutes) required for warehousing when material purchase arrangements are urgently requested.

FIG. 3 is a diagram illustrating a data structure of configuration information managed by the configuration information master 132 according to the embodiment.
FIG. 3 shows an example of information of the configuration information master 132 stored in the storage device 2 shown in FIG.

  The configuration information master 132 is input from, for example, an operator or another computer system via the master input circuit 101 shown in FIG. The configuration information master 132 is basic information and is invariant information. The configuration information is information on the part number and the number of parts necessary for the production of the product. The configuration information master 132 stores the model, line, equipment, lane, part part number, and number, and the information includes the model, Stored for each line, facility, and lane. The model is a number unique to the product to be produced and is a designation. Line is the name of the production line. Equipment is the production equipment that constitutes a line. Lane is the feeder number of the equipment. The part product number is the same number as the part product number in the material information master 131 described above, and is associated with the part product number in the material information master 131 described above. The number is the number of parts used for production on the production line of the model to be produced.

FIG. 4 is a diagram illustrating a data structure of switching time information managed by the switching time information master 133 according to the embodiment.
FIG. 4 shows an example of information of the switching time information master 133 stored in the storage device 2 shown in FIG.

  The switching time information master 133 is input from, for example, an operator or another computer system via the master input circuit 101 shown in FIG. The switching time information master 133 is basic information and invariable information. The switching time information is information on the time required to switch the model in the production line, and the switching time information master 133 stores the switching time required for switching the line, the model before switching, the model after switching, and the model. The information is stored for each line, the model before switching, and the model after switching. Line is a line name. The model before switching is a product-specific number that is produced before switching the model. The model after switching is a product-specific number produced after switching the model. The switching time is a time (unit: minute) required when switching from the model before switching to the model after switching on the corresponding line.

FIG. 5 is a diagram illustrating a data structure of production tact information managed by the production tact information master 134 according to the embodiment.
FIG. 5 shows an example of information in the production tact information master 134 stored in the storage device 2 shown in FIG.

  The production tact information master 134 is input from, for example, an operator or another computer system via the master input circuit 101 shown in FIG. The production tact information master 134 is basic information and immutable information. Production tact information is information on the time required to produce a product on the production line, and the production tact information master 134 stores the line, model, and tact, and the information is stored for each line and model. Has been. Line is a line name. The model is a number unique to the product to be produced. The tact is the time (unit: seconds) required to produce one corresponding model on the corresponding line.

FIG. 6 is a diagram illustrating a data structure of production plan information managed by the production plan information 135 in the embodiment.
FIG. 6 shows an example of the production plan information 135 stored in the storage device 2 shown in FIG.

  The production plan information 135 is input from, for example, an operator or another computer system via the above-described production plan input circuit 102 shown in FIG. The production plan information 135 is information to be added / modified, and will be described later in a series of processes of the present invention.

  The production plan information is an initial production plan and is information indicating when and on which line a product is to be produced. , Line, model, scheduled production date, planned number of units are stored. Every one is remembered. Lot No. Is a unique number indicating a production plan, and is a number determined by the production plan input circuit 102 or the like. Line is the name of the line scheduled to be produced. The model is a product-specific number that is the same as the model of the configuration information master 132 described above, and is associated with the model of the configuration information master 132 described above. The scheduled production date is the scheduled date for producing the model. The planned number is the number to be produced.

FIG. 7 is a diagram illustrating a data structure of inventory information managed by the inventory information 136 in the embodiment.
FIG. 7 shows an example of information of the inventory information 136 stored in the storage device 2 shown in FIG.

  The inventory information 136 is input from, for example, an operator or another computer system via the above-described inventory input circuit 103 shown in FIG. The inventory information 136 is information to be added / modified and will be described later in a series of processes of the present invention. The inventory information is information indicating the part number and the remaining number of parts existing in the warehouse or line, and the inventory information 136 stores the reel ID, the part part number, the remaining number, the location, the line, the equipment, and the actual warehousing date. The information is stored for each reel ID. The reel ID is information unique to each component and is a number for which the inventory input circuit 103 is determined. The part product number is a number unique to the part. The remaining number is the remaining number of parts for each reel ID. The location is information indicating whether the part is located on a line or a warehouse. The line is information indicating which line is where the part is located. The equipment is information indicating which equipment is used when the location of the part is a line. The actual warehousing date is the date when the part is received.

FIG. 8 is a diagram illustrating a data structure of delivery schedule information managed by the delivery schedule information 137 according to the embodiment.
FIG. 8 shows an example of delivery schedule information 137 information stored in the storage device 2 shown in FIG.

  The delivery schedule information 137 is input from, for example, an operator or another computer system via the inventory input circuit 103 shown in FIG. Delivery schedule information 137 is information to be added / modified, and will be described later in a series of processes of the present invention. The delivery schedule information is information on materials to be delivered in the future, and the delivery schedule information 137 includes an order No. , Part number, scheduled quantity, scheduled date / time, and status are registered. Each is registered. Order NO. Is information specific to parts arrangement and is a number determined by another system. The part product number is a number unique to the part. The scheduled receipt quantity is an arrangement quantity for each part. The scheduled receipt date / time is the date and time when the arranged parts are received. The state represents the progress of warehousing, and there are unstocked and received.

  FIG. 9A to FIG. 9C are diagrams showing a data structure of startable / continuous production time information managed by startable / continuous production time information 138 according to the embodiment, and are shown in a table format. ing.

FIGS. 9A to 9C show an example of information of the startable / continuous production time information 138 stored in the storage device 2 shown in FIG.
The startable / continuous production time information 138 is information created by the above-described shortage calculation / plan determination circuit 104 shown in FIG. 1, and the creation method will be described later in a series of processes of the present invention. The startable / continuous production time information is information indicating the shortage and the production possible state, and shows the relationship between the continuous production possible time and the number of production for each model in consideration of the shortage. The ready / continuous production time information 138 includes lot No. The planned order, line, model, planned number of units, available start time, and continuous production time are registered. Continuous production is the time from the start of production until the production stops due to missing or full production. It is registered for each unit that is found to be capable of continuous production from the stockout calculation. Lot No. Is a unique number indicating a production plan. The planning order is a number indicating a model that is prioritized on the same line. For example, priority can be given to a model that has the longest continuous production time, or priority can be given to production of a product with a close delivery date. Line is the name of the line scheduled to be produced. The model is a number unique to the product to be produced. The planned number is the number that can be continuously produced without missing items. The available time is the start time of continuous production from the planning time.

  The startable / continuous production time information 138 is information that is corrected as needed by the shortage calculation / plan determination circuit 104. FIG. 9A shows the shortage corresponding to the initial production plan and the initial state of the ready state. The shortage in a state where the shortage information or the like is not taken into consideration and the production possible state are illustrated. FIG. 9B illustrates a state where the shortage and the production possible state are corrected when there is no shortage, and FIG. 9C illustrates the shortage and the production possible state when there is a shortage. The corrected state is illustrated.

Fig.10 (a)-FIG.10 (e) are figures which show the data structure of the production plan review information managed by the production plan review information database in embodiment.
10A to 10E show an example of the production plan review information 139 stored in the storage device 2 shown in FIG.

  The production plan review information 139 is information created by the above-described shortage plan / plan decision means 104 shown in FIG. The missing item plan / plan decision means 104 creates a production plan for when there is no missing item and when there are 1 to N missing items, and makes the production plan review information 139, and adjusts when the completion time is the shortest. Determine the production plan. The creation method will be described later in a series of processes of the present invention. The production plan review information is information indicating the result of adjusting the production plan, and the production plan review information 139 includes an evaluation pattern, a lot number, and the like. , Line, model, production date / time, planned number, production end time are registered. For example, production plan review information is registered, which has a high operation rate of the production process and can minimize the time required to complete a product. The evaluation pattern indicates an evaluation standard when reviewing the production plan. Lot No. Is a unique number indicating a production plan. Line is the name of the line scheduled to be produced. The model is a number unique to the product to be produced. The production date / time is the scheduled production date and start time. The planned number is the number produced according to the corresponding adjustment result. The production end time is a time required until the production for the planned number is finished.

  10 (a) to 10 (e) respectively show different evaluation patterns, and FIG. 10 (a) shows the initial state of all the planned adjustment results planned for no missing parts, FIG. FIG. 10 (c) shows the result of the production plan of the lot for which continuous production ends first, that is, the state where the first continuous production is completed, which is recreated in consideration of the warehousing schedule and the like. Fig. 10 (d) and Fig. 10 (e) are the results of the state in which the first continuous production, which was re-created considering the warehousing schedule when there is a shortage, has been completed. Examples of all plan adjustment results that were changed when they were present are shown.

Fig.11 (a)-FIG.11 (c) are figures which show the data structure of the evaluation result information managed by the evaluation result information database in embodiment.
11A to 11C show an example of information of the evaluation result information 140 stored in the storage device 2 shown in FIG.

The evaluation result information 140 is information created by the above-described shortage calculation / plan determination circuit 104 shown in FIG. 1, and the creation method will be described later in a series of processing of the present invention.
The evaluation result information 140 is information indicating the evaluation result of the revised production plan. In the evaluation result information 140, an evaluation pattern, completion time, number of switching times, switching time, number of missing items, and missing item time are registered. . The evaluation pattern indicates an evaluation standard when reviewing the production plan. Completion time is the time required to implement an adjusted production plan and produce all products. The number of times of switching is the number of times of model switching required when implementing the adjusted production plan. The switching time is a switching time required when the adjusted production plan is executed. The number of missing items is the number of times that a missing item occurs when an adjusted production plan is executed. The out-of-stock time is a time during which production is stopped due to a material shortage required when the adjusted production plan is executed.

  11A is a result of the state after all evaluations are performed, FIG. 11B is a result of a state in which the first continuous production without missing parts is completed, and FIG. The example of the state where the second continuous production is completed is shown.

Next, a series of processing of the present invention will be described based on the flowchart of FIG.
FIG. 12 is a diagram showing an outline of the entire process executed by the production plan adjusting apparatus according to the embodiment.

  Step S101 in FIG. 12 is a step for inputting a production plan, and the production plan information is stored in the production plan information 135 via the production plan input circuit 102 in FIG. Details of the production plan information 135 are shown in FIG. In the production plan information 135 shown in FIG. 6, how many products are produced on which line, and the production date are registered.

  Step S102 in FIG. 12 is a step for inputting stock, and the stock information is stored in the stock information 136 via the stock input circuit 103 in FIG. Details of the inventory information 136 are shown in FIG. In the inventory information 136 of FIG. 7, the part product number, the remaining number of parts, and the like are registered for each reel ID unique to the part.

  Step S103 in FIG. 12 is a step for calculating the shortage and determining the plan. The shortage calculation / plan determination circuit 104 in the central processing unit 1 in FIG. 1 determines the production plan. Details will be described later with reference to FIG.

  In step S104 of FIG. 12, it is determined whether or not step S103 has been performed on all the lines. If so, the production plan is terminated, and if not, step S103 is performed again.

Next, details of the stockout calculation / plan determination in step S103 in FIG. 12 in the series of processes according to the present invention will be described with reference to the flowchart in FIG.
FIG. 13 is a diagram showing a stockout calculation / plan determination process executed by the production plan adjusting apparatus according to the embodiment.

Step S131 in FIG. 13 will be described.
In this step, the production plan information 135, the inventory information 136, the delivery schedule information 137, the material information master 131, the configuration information master 132, and the production tact information master 134 are input in the missing part calculation / plan determination circuit 104 in step S101. The start / continuous production time information of the produced production plan is calculated, and the start / continuous production time information 138 is created and stored in the storage device 2. For example, for the models AAA, BBB, CCC, and DDD included in the production plan information 135 shown in FIG. 6, the part number and the number of parts configured from the configuration information master 132 shown in FIG. 3 are extracted. That is, each part part number a, e, f required for production of the model AAA and the number of parts 2 (pieces), 1 (pieces), 1 (pieces), each part part number b required for the production of the model BBB , E, f and the number of parts 3 (pieces), 1 (pieces), 1 (pieces), part numbers c, e, f required for production of the model CCC and the number of parts 4 (pieces), 1 (piece), 1 (piece), each part number d, e, f required for production of the model DDD and the number of each part 2 (piece), 1 (piece), 1 (piece) are extracted.

  Next, the lot number of the production plan information 135 shown in FIG. The required number of each part that satisfies the planned number corresponding to is calculated. Lot No. The number required for the part number “a” of P0001 is 500 (units) × 2 (pieces) = 1000 (pieces) based on the planned number of production plan information 135 in FIG. 6 and the number of configuration information masters 132 in FIG. The number required for this is 500 (units) × 1 (pieces) = 500 (pieces), and the number required for the part number f is 500 (units) × 1 (pieces) = 500 (pieces). Similarly, lot no. The number required for the part number b of P0002 is 1200 (units) × 3 (pieces) = 3600 (pieces) based on the planned number of production plan information 135 in FIG. 6 and the number of configuration information masters 132 in FIG. Required for the part number f is 1200 (units) × 1 (pieces) = 1200 (pieces), lot number. The number required for the part number c of P0003 is 1400 (units) × 4 (pieces) = 5600 (pieces), and the number required for the part number e is 1400 (units) × 1 (pieces) = 1400 (pieces), The number required for the part number f is 1400 (units) × 1 (pieces) = 1400 (pieces). The number required for the part number d of P0004 is 1000 (units) × 2 (pieces) = 2000 (pieces), and the number required for the part number e is 1000 (units) × 1 (pieces) = 1000 (pieces). The number required for the part number f is 1000 (units) × 1 (pieces) = 1000 (pieces).

  Further, the inventory information 136 shown in FIG. Allocate the necessary number of each required part number for each part and check whether the planned number is achieved. Lot No. In P0001, the necessary number for the part product number a is 1000 (pieces), but the remaining number of the part product number a is 600 (pieces) from the inventory information 136 shown in FIG. 7, and from the configuration information master 132 shown in FIG. Since the number of the part number a is 2, when the production of 600 (pieces) / 2 (pieces / unit) = 300 (units) is produced, a missing part occurs in the part having the part number a. . The number required for the part number e is 500 (units) × 1 (pieces) = 500 (pieces) from the production plan information 135 in FIG. 6, and the number required for the part number f is also 500 to 500 from the production plan information 135 in FIG. (Stands) × 1 (pieces) = 500 (pieces), and from the inventory information 136 of FIG. 7, the remaining number of the part product number e is 5200 (pieces) and the remaining number of the part product number f is 4600 (pieces). It can be seen that the part number e and the part number f satisfy the production plan.

  Similarly, lot no. In P0002, the number required for the part product number b is 3600 (pieces), but the remaining number of the part product number b is 1500 (pieces) (600 pieces + 900 pieces) from the inventory information 136 shown in FIG. Since the number of the part product number b from the configuration information master 132 shown is 3, a shortage occurs when 1500 (pieces) / 3 (pieces / unit) = 500 (units) is produced. Lot No. In P0003, the required number for the part product number c is 5600 (pieces), but the remaining number of the part product number c is 800 (pieces) (100 pieces + 300 pieces + 400 pieces) from the inventory information 136 shown in FIG. From the configuration information master 132 shown in FIG. 3, the number of the part number c is 4. Therefore, when the production of 800 (pieces) ÷ 4 (pieces / unit) = 200 (units) occurs, a shortage occurs. Become. Lot No. In P0004, the required number for the part product number d is 2000 (pieces), but the remaining number of the part product number d is 200 (pieces) from the inventory information 136 shown in FIG. 7, and from the configuration information master 132 shown in FIG. Since the number of the part number d is 2, 200 (pieces) ÷ 2 (pieces / unit) = 100 (units), a shortage will occur at the time of production.

  Next, using the delivery schedule information 137 shown in FIG. 8, the lot number in which the shortage of the production plan information 135 shown in FIG. We will make provisions. Lot No. In P0001, an additional 1000 (pieces) is required for the part number a to achieve the planned number based on the above calculation. However, since the inventory information 136 shown in FIG. ) I know it is out of stock. On the other hand, assuming that the planning start time is 2:00 on January 22 from the scheduled arrival date and time of the delivery schedule information 137 shown in FIG. 8, 1000 (pieces) are delivered after 240 (minutes). I understand that. Since the number of missing parts of the part number a is 400 (pieces), lot No. It can be seen that the planned number of P0001 is satisfied. Next, from the production tact information master 134 shown in FIG. The time required to produce 300 (units) before P0001 is out of stock is 300 (units) × 36 (seconds) = 10800 (seconds), that is, 180 (minutes). It can be seen that production is stopped due to a shortage for 240 (minutes) -180 (minutes) = 60 (minutes) until production can be resumed (when continuous production is performed).

  To summarize the above, lot no. P0001 can be started immediately, but its continuous production time is 180 (minutes), and it can be seen that it can be produced until the completion of the plan by using parts delivered after 240 minutes. The information is stored in the startable / continuous production time information 138 shown in FIG. 9A (part (i) shown in FIG. 9A). Similarly, lot no. P0002 and P0003 are calculated and stored in the startable / continuous production time information 138 shown in FIG. 9A (parts (ii) and (iii) shown in FIG. 9A, respectively).

  Finally, lot no. When calculating for P0004, out of the number of each part part number required to meet the planned number, the part part number d is 2000 (pieces) according to the above calculation, while the inventory that can be reserved and the delivery schedule 7 is 200 (pieces) +1200 (pieces) = 1400 (pieces) based on the remaining number of inventory information 136 shown in FIG. 7 and the expected storage quantity of delivery schedule information 137 shown in FIG. Then, it turns out that the planned number cannot be satisfied. At this time, it can be seen from the sudden arrangement lead time of the material information master 131 shown in FIG. 2 that if the part is arranged immediately, it will be delivered after 2100 (minutes), and the planned number of units will be satisfied using that part. . The result is stored in the startable / continuous production time information 138 shown in FIG. 9A (part (iv) shown in FIG. 9A).

Next, step S141 in FIG. 13 will be described.
In this step, the shortage calculation / plan determination circuit 104 determines from the available / continuous production time information 138 that the production plan has the longest continuous production time from the latest when the shortage is 0 to N times. The continuous production time is extracted and stored in the production plan review information 139. At this time, a production plan can be created by prioritizing various predetermined items. For example, even if the production process is stopped due to a shortage, it may be selected that the production is continued with the same model after the material is delivered without switching the model.

  For example, in the case of zero out-of-stock items (selecting a lot number that can be continuously produced without missing items), the lot No. can be determined from the start / continuous production time information 138 shown in FIG. P0001 can be started immediately (that is, the startable time is 0), and its continuous production time is 180 (minutes). Lot No. P0002 can also be started immediately (that is, the startable time is 0), its continuous production time is 300 (minutes), lot no. P0003 can also be started immediately (that is, there is zero startable time), and its continuous production time is 120 (minutes). Lot No. P0004 can be started immediately (that is, the startable time is 0), and its continuous production time is 60 (minutes). At this time, the plan with the longest continuous production time from the latest is the lot number. In P0002, the continuous production time is 300 (minutes), and the result is stored in the production plan review information 139 as shown in FIG.

  Next, in the case of one shortage (a shortage occurs once and a lot number that can be continuously produced is selected), the start / continuous production time information 138 shown in FIG. If a shortage occurs once during production, lot no. P0001 indicates that the first shortage time is the continuous production of the first production from the available production time of the second production from the part (i) of the production possible / continuous production time information 138 shown in FIG. 9A. The time is subtracted, that is, (240 minutes−180 minutes) = 60 (minutes), and the total continuous production time is (180 minutes + 120 minutes) = 300 (minutes). Lot No. P0002 indicates that the first shortage time from the startable / continuous production time information 138 (ii) shown in FIG. 9A is the continuous production of the first production from the second production startable time. The time is subtracted, that is, (1380 minutes−300 minutes) = 1080 (minutes), and the total continuous production time is (300 minutes + 180 minutes) = 480 (minutes). Lot No. P0003 indicates that the first shortage time from the startable / continuous production time information 138 (iii) shown in FIG. 9A is the continuous production of the first production from the second production startable time. The time is subtracted, that is, (1020 minutes−120 minutes) = 900 (minutes), and the total continuous production time is (120 minutes + 300 minutes) = 420 (minutes). Lot No. P0004 is the continuous production of the first production from the available production time of the second production from the part of (iv) of the possible production / continuous production time information 138 shown in FIG. 9A. The time is subtracted, that is, (1020 minutes−60 minutes) = 960 (minutes), and the total continuous production time is (60 minutes + 360 minutes) = 420 (minutes). At this time, the plan having the longest continuous production time from the latest while allowing the shortage is the lot number. P0001, and this result is stored in the production plan review information 139 as shown in FIG.

Next, step S142 in FIG. 13 will be described.
In this step, the shortage calculation / plan determination circuit 104 uses the lot number assigned this time to the production end time for each lot already assigned to the production plan review information 139. The start / continuous production time information 138 is updated / stored from the switching time information master 133 taking into account the switching time that matches the pre-switching model and the switching model.

  For example, in the case of zero missing items (selecting a lot number that can be continuously produced without missing items), from the production plan review information 139 shown in FIG. Taking into account 300 (minutes), which is the production end time of P0002, and from the switching time information master 133 shown in FIG. From BBB, the model of P0002, lot no. In consideration of the switching time (each 60 minutes) to AAA, CCC, and DDD which are each model of P0001, P0003, and P0004, each lot No. Update the available start time and continuous production time. Specifically, lot no. P0001 is a part number a that can be started only after 240 (minutes) in the state of startable / continuous production time information 138 shown in FIG. When the shortage is resolved and the production operation is started after 300 minutes, the continuous production time of (180 minutes + 120 minutes) = 300 (minutes) will be secured, and this information can be started. Register in the time information 138. During this first 300 minutes, lot no. Production of PBB BBB. However, lot no. From BBB, the model of P0002, lot no. When switching to AAA, which is a model of P0001, 60 (minutes) is required from the switching time information master 133 shown in FIG. 4, so the possible start time is (300 minutes + 60 minutes) = 360 (minutes). Similarly, lot no. P0003 and P0004 are updated, and start / continuous production time information 138 is updated as shown in FIG. 9B.

  Next, in the case of one shortage (one shortage is allowed once and a lot number that can be continuously produced is selected), the lot assigned this time is determined from the production plan review information 139 shown in FIG. No. In consideration of 360 (minutes), which is the production end time of P0001, and from the switching time information master 133 shown in FIG. From AAA, which is the model of P0001, lot no. In consideration of the switching time (60 minutes each) to BBB, CCC, and DDD, which are models of P0002, P0003, and P0004, each lot No. Update the available start time and continuous production time. Specifically, lot no. In P0002, the available start time is 360 (minutes), and lot no. From AAA, which is the model of P0001, lot no. When switching to the BBB, which is a model of P0002, 60 (minutes) is required from the switching time information master 133 shown in FIG. 4, so the possible start time is (360 minutes + 60 minutes) = 420 (minutes). Similarly, lot no. P0003 and P0004 are updated, and start / continuous production time information 138 is updated as shown in FIG.

Next, step S143 in FIG. 13 will be described.
In this step, the shortage calculation / plan determination circuit 104 uses the accumulated production time, the number of switching times, the switching time, the number of missing items, and the shortage time until the production plan at S142 is completed in the evaluation result information 140. Update and register.

  For example, in the case of 0 missing items (a lot number that can be continuously produced without selecting a missing item is selected), the completion time is the production end time based on the production plan review information 139 shown in FIG. 300 (minutes), switching, and shortage are set to 0, and the evaluation result information 140 is updated / registered as shown in FIG. 11B.

  In the case of one shortage (only one shortage is allowed and a lot number that can be continuously produced is selected), the completion time is the production end time from the production plan review information 139 shown in FIG. A certain 360 (minutes), the number of times of switching is set to 0, the shortage time is set to once (60 minutes), and the evaluation result information 140 is updated / registered as shown in FIG.

Next, step S144 in FIG. 13 will be described.
In this step, if a production plan remains in the startable / continuous production time information 138 and there is a model for which production has not been completed (there is a plan in which continuous production time remains), the process returns to S141 again. If no production plan remains, the process proceeds to the next step, S145.

Next, step S145 in FIG. 13 will be described.
In this step, the shortage calculation / plan determination circuit 104 compares and evaluates, for example, the completion time between the previous production plan registered in the evaluation result information 140 and the production plan registered this time. If the evaluation is better than the previous time, the process proceeds to S146. If the evaluation is bad, the process proceeds to S147. For evaluation, the production plan may be selected using the time required to produce the product as an evaluation item. However, the evaluation items include completion time, number of switching times, switching time, number of missing items, missing item time, etc. It can be selected by the evaluator, and can be set in advance in the shortage calculation / plan determination circuit 104.

Next, step S146 in FIG. 13 will be described.
In this step, the shortage calculation / plan determination circuit 104 deletes the previous evaluation result from the evaluation result information 140 and leaves the current evaluation result. In addition, the previous evaluation pattern result is deleted from the production plan review information 139, and the current evaluation pattern result is left.

Next, step S147 in FIG. 13 will be described.
In this step, the shortage calculation / plan determination circuit 104 deletes the current evaluation result from the evaluation result information 140 and leaves the previous evaluation result. Further, the result of the current evaluation pattern is deleted from the production plan review information 139, and the result of the previous evaluation pattern is left.

Next, step S148 in FIG. 13 will be described.
In this step, the shortage item calculation / plan determination circuit 104 initializes the ready / continuous production time information 138, and sets the ready / continuous production time information 138 shown in FIG. 9A.

Next, step S149 in FIG. 13 will be described.
In this step, if all the missing part allowance patterns when N missing parts are allowed are completed, the process returns to S141. If completed, the process proceeds to S150.

  For example, in the case of one shortage (only one shortage is allowed and a lot number that can be continuously produced is selected), the shortage occurrence timing that is a place where the shortage is allowed is the first (first time) The second time (the first continuous production does not allow the shortage, only the second continuous production allows the shortage), ... up to the nth time If all the patterns are not completed, the process proceeds to S141. If all the patterns are completed, the process proceeds to S150.

Next, step S150 in FIG. 13 will be described.
In this step, it is evaluated whether the information is updated in the evaluation result information 140 in the current shortage number (N times). If updated, N = N + 1 and the process returns to S141. If it is not updated, good evaluation cannot be obtained even if the number of missing parts is increased further. Therefore, the evaluation result stored in the evaluation result information 140 is presented as the best one, and the production plan corresponding to this is produced. I do.

  When completion time is selected as an evaluation target in the shortage calculation / plan determination circuit 104, there are two best evaluation results as shown in the evaluation result information 140 of FIG. The information 139 is as shown in the production plan review information 139 shown in FIGS. 10 (d) and 10 (e).

  Incidentally, in the evaluation result information 140 shown in FIG. 11A, the evaluation pattern with no missing part is evaluated as the best result until the shortage is evaluated once in the evaluation pattern in step S145. The information 140 is stored in the information 140, and the production plan review information 139 is as shown in FIG.

  Here, when the above-described embodiment is performed by the conventional production plan adjustment method, lot no. Since P0001, P0002, P0003, and P0004 are performed in order, waiting for receipt of materials occurs when there is a shortage, and it takes 65 hours to complete the four types of lots. However, by using this production plan adjusting apparatus, it can be shortened to 49 hours, and in the above-described embodiment, a production plan that can reduce the time by 20% or more than the conventional one can be provided.

Conventionally, since the production plan is adjusted only by information on the delivered material stock, it is very difficult to review the production plan when a shortage occurs.
In the present invention, even if a shortage occurs, a plurality of production patterns can be created on the production plan adjustment device, and a production plan can be made to minimize the time required to complete the product. The problem that a product is generated and a production plan cannot be made is solved.

  According to the present invention, not only the materials that have been delivered at present, but also materials that are waiting to be delivered, or based on the shortage calculation for each production plan of the product that takes into account the time until materials are delivered after making a sudden arrangement. If there is a shortage after production, the production pattern is switched to another plan that allows for continuous production. Even if a shortage occurs, production is stopped and production is resumed after materials are delivered without switching the model. A computer calculates multiple patterns of production patterns.

  In this way, the system can create multiple production patterns based on the combination of material delivery and the presence / absence of a shortage, and even when there is a shortage of product inventory or material inventory, The production pattern plans can be automatically compared and selected by the computer based on any evaluation item from the pattern, and the time required to complete the product can be minimized, so the material delivery status is considered. However, the best production plan can be created, and the production requirement of the product can be achieved in a short time. As a result, the operation rate of the production process becomes high, and in addition to inventory reduction, it is possible to improve the profit of the factory.

  The present invention makes it possible to easily carry out a production plan that minimizes the time required to complete a product even when there is not enough product inventory / material inventory. Based on this, it is useful for a production plan adjustment device that adjusts a production plan of a product.

DESCRIPTION OF SYMBOLS 1 Central processing unit 2 Storage device 3 Input device 4 Display device 101 Master input circuit 102 Production plan input circuit 103 Stock input circuit 104 Stockout calculation / plan determination circuit 131 Material information master 132 Configuration information master 133 Switching time information master 134 Production tact Information master 135 Production plan information 136 Inventory information 137 Delivery schedule information 138 Available / continuous production time information 139 Production plan review information 140 Evaluation result information

Claims (3)

It has an input circuit, a shortage calculation / planning decision circuit, and a storage device.
In the storage device,
Production plan information, which is information about the production of the product, including the initial production plan;
Configuration information master in which configuration information related to materials necessary for each model that produces the product is registered,
A switching time information master in which switching time information related to the time required when switching the model in the production process is registered;
Inventory information about the inventory of delivered materials,
Delivery schedule information on materials that have been arranged but not yet delivered,
Material information master in which material information related to the lead time when arranging for each material is registered,
Information on the continuous production possible time and production number for each model calculated from the shortage state of the material can be started, continuous production time information,
Production plan review information that is a production plan that reviewed the initial production plan;
Evaluation result information that is an evaluation result of the reviewed production plan is stored,
The input circuit is
The material information master, the configuration information master, the switching time information master, the production plan information, the inventory information and the delivery schedule information are input to the storage device,
The shortage calculation / plan decision circuit
Calculate the startable / continuous production time information from the production plan information, the configuration information, the inventory information, the delivery schedule information, and the material information master,
Furthermore, using the number of occurrences of missing items and the occurrence timing of missing items during production as parameters, calculate the time required to produce all the products and create a plurality of adjusted production plans,
Select the reviewed production plan that takes the shortest time to produce all products, and start the production / continuous production time information and switching time information master from the production plan review information and the evaluation result information A production plan adjustment device characterized by updating.   2. The production plan adjusting apparatus according to claim 1, wherein the production plan is adjusted by giving priority to a model having the longest continuous production time based on the startable / continuous production time information.   Based on the information on the availability and continuous production time, the production plan is adjusted by giving priority to production after waiting for materials to be delivered without switching the model even if the production process stops due to a shortage. The production plan adjusting apparatus according to claim 1.

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