JP3264022B2 - Management support processing method for order instruction card - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

2. Description of the Related Art In many assembly factories, production activities are continued by receiving an appropriate number of parts from a part maker at an appropriate timing. The present invention allows components (and, more generally, articles) to be
The present invention relates to a method for supporting proper order management by providing useful information for appropriately managing orders so as not to be out of stock.

[0002]

2. Description of the Related Art As a technique for appropriately managing orders, a technique called a "kanban system" is well known.
In this method, a card called "Kanban" is used. This “kanban” is given to the article user together with the article when the article is delivered, and is returned to the article supplier after use of the article as an indication of the order. The goods supplier receiving the "Kanban" delivers new parts together with the "Kanban". According to this cycle, the cycle in which only used articles are ordered and delivered is repeated, and articles are naturally replenished later.

[0003]

The delivery of articles is made for each flight. This cycle of delivery or delivery is represented by three constants abc. This constant is b
This means that the delivery will be made c flights later than the ordered flight. In the case of the above-mentioned prior art, as long as the value of abc is constant, a cycle that only used parts are refilled later is maintained. However, the delivery cycle is reviewed by the production manager after taking into account fluctuations in demand, changes in production conditions, changes in traffic conditions, and the like, and is changed as necessary. When the delivery cycle is changed, if it is left to the flow of "Kanban", shortage of goods and excessive inventory will occur temporarily.

Conventionally, experienced production managers have artificially adjusted the number of "kanbans" to prevent shortage or excessive inventory when the delivery cycle is changed. However, the process of artificially adjusting the number of "kanbans" to keep the stock amount within an appropriate range requires much experience and intuition, and still does not always work. Therefore, the fact is that orders are usually managed in anticipation of safety, with the expectation that inventory will temporarily increase.

[0005]

In order to solve such a problem, according to the present invention, a cycle of a delivery cycle in which an article ordered at the time of article delivery is delivered with a delay of a predetermined flight (flight c). In order to properly manage the order instruction card when the number of delayed flights is changed from c1 to c2,
We created a support processing method to be performed by This support processing method
The law governs order management computers, other computers, and
And these devices are communicably connected
First, the delivery site provided by another computer
Use plan data for each flight from vehicle and given production plan
And calculate the usage plan data for each flight
Computer, and then to the order management computer.
Order management based on received flight plan data for each flight
The computer for use identifies the flight c1 earlier than the flight whose number of delayed flights is changed from c1 to c2, and determines the ordering plan of the identified flight as the flight whose number of delayed flights is changed and (c2-1). ) The process of summing up the article use plan up to the delayed flight and the process in which the number of delayed flights is changed (c1
-1) The process of setting the ordering schedule for each flight from the previous flight to the flight one flight earlier than the flight whose number of delayed flights is changed to zero and the ordering plan for the flight whose delayed flight number is changed to c2 flight And performing a process of setting the average value of the goods use plan within the period of delayed delivery to calculate order plan data for each flight, and
Order planning data to the ordering machine, and the ordering machine
Based on the order plan data for each flight sent,
The number of delayed flights will be changed by issuing a show card
It is specially designed to prevent shortage of goods before c2
Sign.

[0006]

According to this method, a modified order in which only the goods used between the cycle-changed flight (ie, the first flight whose number of delayed flights is changed) and the flight delayed by c2 thereafter is delivered by the cycle-changed flight. A plan is drawn up. In other words, a revised order plan that does not cause a missing item until the flight c2 after the cycle change is drafted. Then, after the cycle change, the same ordering plan as when "Kanban" is left to the natural flow is drafted. As described above, according to the present invention, a modified order plan for placing an order ahead of schedule by an amount that does not cause a shortage is drafted in advance. For this reason, the production manager can appropriately manage the order instruction card based on the modified order plan or after making necessary corrections based on the modified order plan.

[0007]

Next, an embodiment of the present invention will be described. FIG. 1 shows the configuration of an apparatus for implementing the method according to the present invention, FIGS. 2 and 3 show the flow of processing executed by this apparatus, and FIG. 4 shows an example of the processing result. FIG.
Delivery cycle is abc
Indicated by This indicates that the delivery is made b times a day, and the delivery is delayed from the ordered flight by c flights. In the case of FIG.
Delivered three times a day four times a day, three days a day, one on the third to sixth days
Delivered twice a day with one flight delay, 4 times a day on days 7-8
This indicates that the delivery will be delayed.

[0008] Such a delivery cycle is given, and furthermore, the production quantity (ie, the quantity of goods or parts used) during the delivery cycle.
Given, the average usage per flight can be determined. FIG. 4 illustrates a case where a production plan using only one unit every day is given. On the day b = 4 (that is, 1-2, 7-8 days), the use plan for each flight is “1 /
4 ”and“ 1 ”on the day of b = 2 (that is, 3 to 6 days).
/ 2 ". This is illustrated in column A of FIG.

Another computer indicated by reference numeral 1 in FIG. 1 calculates a use plan for each flight from a given delivery cycle and a given production plan. The computer 1 is connected to an order management computer 4 via a communication line 2, and usage plan data 3 for each flight calculated by the computer 1 is input to the order management computer 4 via the communication line 2. You. Computer 4 for order management
Has an input / output terminal 5 and a communication line 2
Is connected to the ordering machine 7 via.

The order management computer 4 includes 4a to 4h
It is programmed to execute each process shown in
First, the service-by-flight use plan receiving process 4a operates to receive the flight-by-flight use plan data calculated by the other computer 1. In the case illustrated in FIG. 4, the use plan for each flight shown in the column A is input to the order management computer 4.

When the use plan for each flight is received, an uncorrected (or pre-corrected) order plan calculation processing 4b is executed. This is a process of calculating an order schedule that should occur when “Kanban” is left to the natural flow.
As can be understood from the columns B and B, the service-by-flight use plan (A) is shifted by one flight in the future direction to obtain the uncorrected order plan (B). If "Kanban" is left to the natural flow, it will be shifted by one flight in the future in response to the fact that "Kanban" will be given to the parts supplier as an indication of the order when the next part is delivered after the parts are used. It is.

A phenomenon that occurs when an order is provisionally made based on the uncorrected order plan calculated in this way is shown in FIG. 4 for comparison, and will be described first. The column I in FIG. 4 shows a delivery plan when an order is placed according to the uncensored order plan.
~ 2 days order is 3 flights delayed, 3-6 days order is 1 flight delayed,
The order on the 7th to 8th shows the number of parts to be delivered per flight when the product is delivered four flights late. In the column of I1 in the figure, the delivery ordered three days late on the second day and the order one ordered on the second flight on the third day
This indicates that the delivery that is delayed is delivered at the same time. In addition, the column of I2 indicates that the delivery delayed for three flights ordered on the second day and the delivery delayed for one flight ordered on the first flight on the fourth day are simultaneously delivered. The column of I3 corresponds to the fact that the order on the seventh day is not delivered until four flights are delayed. Column J in FIG. 4 shows the result of calculating the inventory plan by accumulating the difference between the use plan in column A and the delivery plan in column I.

The columns of J1 and J2 indicate that, despite the longer delivery interval, the number of deliveries per delivery does not correspond to that, so that the inventory amount is reduced. If there is no advance stock, the product will be out of stock at this point, and the assembly process will be discontinued. The columns J3 and J4 indicate that inventory is also reduced due to delays in delivery flights.

If the flow of "Kanban" is left as it is, the above-mentioned shortage occurs. To avoid this, the production manager artificially increases the number of "kanbans" in advance, but if the increase is insufficient, the product will be out of stock, and if the increase is excessive, the inventory will be excessive. Therefore, a useful index for rationally adjusting the number of “kanbans” is desired.

[0015] In this embodiment, by modifying the order planning calculation process shown in reference numeral 4c 1, unmodified ordering scheme shown in the column B of FIG. 4 is modified as shown in column C. FIG. 2 shows the flow of the processing executed in the modified order plan calculation processing 4c.
Is shown in

In the processing of FIG. 2, the delivery cycle is “a1 → b1”.
This shows a case where the delivery cycle is changed from “→ c1” to “a2 → b2 → c2.” In the case of FIG. 4, the delivery cycle is changed twice from 2 → 3 days and 6 → 7, and the constants for each change Is as shown in the table below.

In step S1 of FIG. 2, a flight c1 before the first delivered flight after the cycle change (hereinafter referred to as a cycle-changed flight) is specified. As a result, S in FIG.
The flights indicated by the arrows 1a to S1b are specified. In this flight, the order ordered by this flight is delivered in a cycle change flight.

Next, in step S2 in FIG. 2, the total of the usage schedule between the cycle-changed flight and the flight delayed from the cycle-changed flight (c2-1) is calculated . This is indicated by arrows S2a and S2b in FIG. Next, in step S3 of FIG. 2, the order plan of the flight specified in step S1 is corrected to the sum calculated in step S2. This is S in FIG.
This is indicated by arrows 3a to S3b.

Next, in step S4 of FIG. 2, the ordering plan from the flight before the flight (c1-1) before the cycle-changed flight to the flight before the flight with the cycle-changed flight before the flight is set to "zero". As a result, the column shown in S4a of FIG. 4 is corrected to “zero”.
In the case of FIG. 4, when the cycle is changed from 6 to 7 days, C1 =
Because of 1, there is no flight to be corrected to "zero". Next, in step S5 in FIG. 2, the order plan of the cycle-changed flight is set to the average value of the flight-specific use plan within the period of delivery in the cycle after the change. That is, the average value of 3 to 6 days is used as the order plan for the three-day cycle change flight, and the average value of
It will be an order plan for flights that change the daily cycle. This is indicated by arrows S5a and S5b in FIG.

The order plan corrected in this way is shown in FIG.
In column C. Next, the contents of the order plan thus modified will be described. Column D in FIG. 4 shows a delivery plan when an order is placed in accordance with the modified order plan. As is clear from the figure, the one ordered is c
Since the delivery is delayed after the flight, the column D is shifted in the future direction of the flight c from the column C. Here, since the value of c has been changed, the order for the first and second days is indicated by three flights, the order of the third and sixth days is indicated by one flight, and the order of the seventh and eighth days is indicated by four flights in the future direction. ing. The columns D1 and D2 in the figure indicate that orders divided into two are delivered at the same time. In addition, the column of D3 corresponds to the fact that the delivery is not made during that time because the delivery is delayed by four flights.

The column E in FIG. 4 shows the stock plan calculated by accumulating the difference between the use plan and the delivery plan. Column J
As is clear from the comparison with the case of (1), the change in the number of stocks is significantly reduced, and the stock is maintained at an appropriate level regardless of the change in the delivery cycle. In the drawing, E1, E2, and E3 are minimum stocks for preventing shortage of goods due to advance ordering, and minimize an increase in the number of stocks. This temporary increase is promptly resolved as shown in column E4.

As can be understood from the above description, the correction process shown in FIG. 2 calculates a correction order plan that does not cause stockouts and minimizes the increase in stock quantity when the delivery cycle is changed. You can see that Therefore, the production manager can know a reasonable ordering plan, and can manage the actual ordering based on this modified ordering plan or by further correcting based on the special factors of the actual production site. .

As described above, in the present embodiment, the minimum purpose can be obtained up to the processing shown in FIG. 2, but processing for facilitating the production manager is further added. This is shown at 4d to 4g in FIG. 4 is for calculating a delivery plan based on the modified order plan calculated in the process 4c, that is, the delivery plan described with reference to the column D in FIG. Corresponds to processing. The post-correction inventory plan calculation processing 4e in FIG. 1 executes the processing in step S12 in FIG. 3, and calculates the values shown in the column E in FIG. Step S13 in FIG. 3 displays the corrected order plan (column C) calculated in step S3 and the inventory plan (column E) calculated in step S12 together, and provides information to the production manager. It is. At this time, the delivery plan (column D) calculated in step S11 may also be displayed.

From this display, the production manager can know the order plan and the phenomena that occur when the order plan is followed. Then, it is determined whether or not this ordering plan needs to be corrected (step S14). For example, based on the state of the change of the stock quantity shown in columns E1 to E4, the original stock quantity (this is set to zero in FIG. Has been carried over by the appropriate number of stocks.
The number of inventories will be added), and if there is a sudden change in the number of deliveries per flight, the parts supplier's load will fluctuate too much. If it is determined, it must be corrected. Then, an input for further correcting the corrected order plan is made in step S15. In the example shown in FIG. 4, a case is shown in which a correction is made so that 1/4 of the order of the last flight on the sixth day is replaced with the order of the first flight on the seventh day.
Step S15 in FIG . 3 is the correction order plan input processing 4 in FIG.
executed by f.

If the order plan has been corrected, step S1
1 and thereafter are repeated again to calculate the delivery plan and the inventory plan based on the corrected order plan, and display them again. The inventory plan at this time is shown in column H. From the display in this column, the production manager determines whether there is any inconvenience in the corrected order plan (step S14). Here, the inventory plan of "-1/4" is displayed in the column of H1, but it is determined that the column H1 does not actually become out of stock due to the original stock quantity, and it is determined that this ordering plan is sufficient. Then, step S16 is executed. Step S16 is to send an order plan to the ordering machine 7 via the communication line 2. The ordering machine 7 controls the actual ordering based on the transmitted ordering plan. For example, when the correction order plan (column C) is not corrected, the order in column C is executed instead of the order in column B. Assuming now that one order instructing card is used for "1/4", one card at a time is sent to the parts supplier by the flights in columns B1 to B3. However, since it is more appropriate to make this a column of C, the ordering machine 7 increases one "kanban" for flight B1 (C1) and one "kanban" for flights B2 and B3. Do not collect and issue them one by one. When the correction order plan in column F is adopted, the order of “3/4” is executed by increasing one “kanban” by the flight in column B4 (see column F4).

In this embodiment, the ordering machine 7 is controlled to automatically manage the ordering work. However, the process up to the stage of determining the ordering plan is computerized, and the actual ordering work (work to increase or decrease the number of kanbans) is performed. May be left to human hands.
Also, in the present embodiment, by preparing the processing of 4d to 4g of FIG. 1 (the processing of FIG. 3 is thereby executed),
Although it is easy for the operator to correct the ordering plan, it is not always necessary, and a minimum purpose can be obtained if there is only a process for calculating the corrected ordering plan.

[0027]

According to the present invention, a rational ordering plan that does not cause stockouts when the delivery cycle is changed and that does not cause excessive inventory is required in advance. For this reason, the production manager can relatively easily know the order plan suitable for the actual situation by using this as an index, and the burden can be reduced, and the accuracy of the order plan is also improved.

[Brief description of the drawings]

FIG. 1 shows an embodiment of an apparatus for performing the method.

FIG. 2 is a diagram showing a calculation processing procedure of a modified order plan.

FIG. 3 is a flowchart of an order planning correction process;

FIG. 4 is a diagram illustrating an example of a processing result;

[Description of Signs] Modified order plan calculation processing (FIGS. 2 and 4c) A step of specifying a flight that is c1 flights earlier than the cycle-changed flight;
S3: The process of setting the order plan of the flight earlier than (c-1) to one flight from the cycle-changed flight to “zero”;
S5

────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-3-198152 (JP, A) JP-A-3-142666 (JP, A) JP-A-3-142668 (JP, A) (58) Field (Int.Cl. ⁷ , DB name) G06F 17/60 B65G 1/137 B23Q 41/00

Claims (1)

(57) [Claims] 1. The goods ordered at the time of goods delivery are then
Delivered after predetermined flight (flight c)Delivery cycleIn circulation
When the number of delayed flights is changed from c1 to c2,
Note instruction card properlyComputer is running to manage
Support processing method to perform This support processing method uses an order management computer and other
These devices can communicate with computers and ordering machines.
Is connected to the First, the other computer is given a delivery cycle and
Calculate usage plan data for each flight from the obtained production plan
The usage plan data for each flight is
Data to Next, for each flight sent to the order management computer
Based on the usage plan data, the order management computer  It is c1 flight rather than the flight whose number of delayed flights is changed from c1 to c2
Identify the flight prior to the flight and create an ordering plan for this identified flight,
Flights whose number of delayed flights is changed and then(C2-1) Flightdelay
The sum of the goods use plan up to the last flight, and (c1-1) flights before the flight whose number of delayed flights is changed
One flight before the flight whose number of delayed flights is changed from the previous flight
The schedule of ordering each flight up to a flight to zero and the schedule of a flight whose number of delayed flights is changed are delivered with a delay of c2 flights.
The process of making the average value of the goods use plan during the product periodTo
Execute to calculate order plan data for each flight, and issue
Send the planning data to the ordering machine, The ordering plan data for each flight from which the ordering machine was sent
By issuing an order instruction card based on Shortage occurs between c2 flight after the flight where the number of delayed flights is changed
Do not Management support for order instruction card
SupportprocessingMethod.