JP3292027B2 - Delivery timing instruction card management device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for managing a delivery timing instruction card for a parts consumer to deliver a predetermined number of parts to a parts supplier by a predetermined delivery flight, and in particular, to a minimum instruction quantity per one delivery instruction. The present invention relates to a management device for a delivery timing instruction card in a case where is determined.

[0002]

2. Description of the Related Art Hitherto, as an important factor for improving the efficiency of product production management in a factory, there is management of parts procurement. If a production plant (parts consumer) lacks necessary parts, the production cannot be performed. Therefore, it is necessary to avoid shortage of parts as much as possible. On the other hand, having parts unnecessarily in stock causes problems such as requiring extra stock space. Therefore, it is desirable to procure parts that satisfy both of these requirements and that do not cause stockouts with minimum inventory.
In particular, in the case of products manufactured using a large number of different parts, such as automobiles, it is very important to efficiently procure the parts.

[0003] As such a parts procurement method, there is a procurement method called a "kanban" method. In this method, on the premise that consumed parts are consumed again,
For example, a delivery instruction is issued by a delivery timing instruction card (hereinafter, referred to as a kanban) to a part ordered from each parts factory (parts supplier) based on the parts plan usage amount on a monthly basis. The kanban has information for delivering a predetermined part to a predetermined place on a predetermined date, and is delivered to a production factory together with the part. Normally, parts are packed in a box, and one part box corresponds to one kanban. Then, by using the parts, the kanban used for the delivery is removed from the parts box. A removed kanban is hereinafter referred to as a detached kanban. After that, the separated Kanban is collected, put on a delivery instruction flight at a predetermined frequency, and transported to a parts factory. Here, the return flight of the normal delivery flight is used as the delivery instruction flight. Then, the parts ordered by the kanban are delivered from the parts factory to the production factory by delivery service. Thus, one cycle of the kanban is configured.

[0004] In the delivery instruction using the kanban as described above, when the production is reduced based on the production plan, the number of kanbans to be used in the delivery instruction in advance so that the number of deliveries on the production reduction day becomes a predetermined number. Gradually decrease. In other words, kanban management is performed such that the number of kanbans corresponding to the reduced amount of production is subtracted from the number of kanbans collected by consuming parts.

[0005]

However, at the time of delivery instructions due to extraordinary kanbans, consumption is not provided to the parts supplier in order to equalize the number of parts delivered and to secure a predetermined amount of cargo on the delivery flight for delivering parts. Even when the number of parts is reduced, it is necessary to give a delivery instruction using a predetermined number or more of kanbans. The minimum number of kanbans, that is, the minimum number of sheets, is a fixed value arbitrarily determined based on the experience of the delivery instruction manager for each part number of each part, and is not changed even if the production plan fluctuates, The minimum delivery instruction amount is determined based on the lower limit number. Therefore, if the number of parts to be consumed is less than the expected number of parts to be consumed due to some trouble, the number of kanbans cannot be reduced below the lower limit, even if an attempt is made to reduce the number of kanbans based on the production decrease in the production plan.

That is, as shown in FIG.
+1) When the production plan is reduced at the time of changing to the month, if the number of kanbans is to be reduced by L (scheduled reduction) for the last three outlying kanbans (X3, X2, X1) in the nth month, For example, in the extraordinary kanban X3, even if the scheduled decrease L is subtracted, the number of kanbans can be reduced because the delivery instruction number a3 is equal to or larger than the lower limit number M. But, for example,
When the scheduled decrease L is subtracted from the outlying kanban X2, the number may fall below the lower limit M. In such a case, the shortage S1 with respect to the lower limit number M is advanced ahead of the delivery instruction in the next outlying kanban X1, and the delivery instruction based on the lower limit number M is executed. Therefore, when the delivery instruction is issued based on the outlying kanban X1, the scheduled decrease L and the shortage (advance) S1
Needs to be deducted from Kanban X1. At this time,
As in the previous case, when the shortage S2 occurs with respect to the lower limit number M, the forward processing is further performed for the next delivery instruction number. In other words, the delivery instruction is issued by moving forward the parts scheduled to be issued next time.

[0007] As described above, since the delivery instruction must be repeated ahead of time, the inventory is held by the amount of the advance processing, and the appropriate delivery instruction is given in spite of using the kanban. There is a problem that can not be. That is, even if the component consumption is reduced, there is no means for appropriately changing the lower limit number of sheets, so that an appropriate component delivery instruction cannot be given.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and it is an object of the present invention to automatically change the lower limit number of sheets linked to fluctuations in the consumption of parts and to reduce the number of delivery instructions in advance. It is an object of the present invention to provide a management device for a delivery timing instruction card which can be provided.

[0009]

In order to achieve the above object, a first aspect of the present invention is a method for delivering parts consumed by a parts consumer at a predetermined timing between a parts consumer and a parts supplier. In a delivery timing instruction card management device for giving an instruction, a number recognizing means for recognizing the number of delivery timing instruction cards to be presented to a component supplier based on parts consumption results, and a component supplier according to a component consumption condition. A lower limit number changing means for changing the minimum number of delivery timing instruction cards that can be presented to, a comparing means for comparing the presented number with the minimum number, and as a result of the comparison, when the presented number is smaller than the minimum number, The difference is the number of presentations
To match the minimum number, and the difference
From the number of presentations based on the actual consumption of parts when
A number correction means corrects the calculation to, characterized in that it comprises a.

Here, the part consumption condition is a condition determined based on a planned consumption based on a production plan, an actual consumption based on an actual consumption result, and the like.

According to this configuration, the lower limit number of the delivery timing instruction card is changed in accordance with the fluctuation of the consumption condition of the component, and when the consumption of the component is reduced, the lower limit number is reduced according to the decrease. Therefore, even when the number-of-sheets correcting means makes a correction to match the presented number of sheets with the lower limit number of sheets based on the comparison result of the comparing means, the amount of correction is small and the number of delivery instructions is reduced.

According to a second aspect of the present invention, in the management apparatus for a delivery timing instruction card according to the first invention, the lower limit number of sheets changing means is controlled according to the total number of the delivery timing instruction cards based on a production plan. It is characterized in that the minimum number is changed.

According to this configuration, it is possible to create a correspondence table including the total number of delivery timing instruction cards predetermined by the production plan and the corresponding lower limit number, so that the lower limit number can be quickly changed. It can be carried out.

According to a third aspect of the present invention, in the management apparatus for a delivery timing instruction card according to the first aspect, the lower limit number changing means includes a predetermined number of low consumptions from recent consumption results. Includes extraction means for extracting achievements,
The minimum number is changed based on the low consumption results.

According to this configuration, the lower limit number of sheets is changed based on the consumption results of the parts, so that the delivery instruction in advance can be minimized, and the optimum lower limit number of sheets can be set.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a configuration block diagram of a management device 10 for a delivery timing instruction card (hereinafter, referred to as a kanban) 12 . The management device 10 is a reader 1 that reads the contents of a delivery instruction (for example, a part number, a delivery number, a location, and the like of a delivery part indicated by a bar code) of the extraordinary kanban 12 that is generated when a part is consumed in a production factory or the like.
4 and data relating to the production schedule of the production plan held by an external computer or the like, and the number of rotations of the kanban based on the production plan (the kanban distributed between the production factory and the parts factory in order to consume the parts according to the production plan) Increase / decrease adjustment TB that holds the number of kanban reductions at the time of production fluctuation calculated based on the production plan or the change in the production environment.
L (table) 16 and the lower limit setting in which the lower limit number of kanbans and the like are held based on data relating to past component consumption results and a safety coefficient that determines what percentage of the set number of rotations is the lower limit number. TBL18, the reader 1
4. Kanban processing unit 20 that changes the lower limit number of kanbans and corrects the number of kanbans to be used, based on information from increase / decrease adjustment TBL16, lower limit setting TBL18, etc., and is determined based on the processing results of kanban processing unit 20. It is composed of a delivery instruction section 22 for giving a delivery instruction according to the number of kanbans. The kanban processing unit 20 includes a reading unit 20a that performs a process of reading data from the reduction adjustment TBL16 and the lower limit setting TBL18, a lower limit number changing unit 20b that changes the lower limit number, and the number of outlying kanbans and the lower limit number. A comparison unit 20c for comparing the number of sheets, a number correction unit 20d for correcting the number of kanbans for which a delivery instruction is issued based on the lower limit number of sheets and the comparison result, and the like are included.

The procedure for changing the minimum number of sheets and instructing delivery will be described below with reference to the flowchart shown in FIG. 2 and the schematic diagram in FIG. 3 in addition to FIG. First, when the production plan changes, for example, from the nth month to the (n + 1) th month, and the component consumption decreases based on the production plan, the lower limit number M changes in conjunction with the set number of rotations K of the kanban. An example will be described.

First, a delivery instruction flight i to be subjected to a parts delivery instruction is extracted based on a kanban cycle. here,
This kanban cycle is determined by three variables A, B, and C: "There are B delivery instructions during the A day, and parts are delivered after the C flight counted from the delivery instruction". The reading unit 20a of the kanban processing unit 20 determines a delivery instruction flight i for issuing a delivery instruction based on the extraordinary kanban Xi recognized by the reader 14 based on the variable C (S1).
00). Subsequently, the first delivery instruction flight (variable flight) for the production fluctuation from the production plan via the increase / decrease adjustment TBL16.
t is obtained, and it is determined whether or not the delivery instruction flight i for which the delivery instruction is to be performed is before or after the variable flight t (S101).

In the case of i <t, it is determined that the timing is not the timing of the change of the production plan, and the lower limit number M is set to M = Kn / (C + 1) × s / 1 based on the set number of rotations Kn for n months.
00 (S102). In the above formula, Kn
By using / (C + 1), the set number of outlying kanbans per flight can be calculated. At this time, the delivery is performed with a delay of flight C, but the delay coefficient C is increased by +1 in consideration of a time lag such as a lead time from when the part is delivered to the delivery place to when it is brought to the line actually used. Use what was done. In addition, s is a safety coefficient that determines what percentage of the set number of rotations is the lower limit. For example, s = 5
A value of 0 indicates that the lower limit is 50% of the set number of rotations. When s = 0, it indicates that the lower limit number is not set. The safety coefficient s can be arbitrarily set by a kanban management worker. Therefore, the lower limit number changing unit 20b selects M = Kn / (C
+1) × s / 100, Kn,
The lower limit number determined by the values of C and s is selected and determined (S103). In this case, C and s are often fixed values, and a table is created in which the set number of revolutions Kn and M correspond to each other in a ratio of 1: 1, and selection and determination are performed based on the set number of revolutions Kn. Will be Therefore, in FIG. 3, when the delivery instruction is performed based on the extraordinary kanbans X3, X2, and X1 that occurred before the production fluctuation, the lower limit number is M = Kn / (C + 1).
× s / 100.

On the other hand, if i> t, it is determined that the timing of change in the production plan has passed, and the lower limit number M is set to (n +
1) M = K based on the set number of rotations K (n + 1) in a month
(N + 1) / (C + 1) × s / 100 (S
104). Therefore, the lower limit number changing unit 20b sets the lower limit setting T
M = K (n + 1) / (C + 1) × s /
From among the lower limit numbers specified by 100, the lower limit number determined by the values of Kn, C, and s is selected and determined (S103).
Also in this case, usually, a correspondence table between K (n + 1) and M is created. That is, at the time of a delivery instruction based on a stray kanban that has occurred after production fluctuations, the lower limit is M = K (n +
1) / (C + 1) × s / 100.

Subsequently, the reading unit 20a performs an increase / decrease adjustment TBL.
The kanban reduction number L for the delivery instruction flight i calculated based on the production plan and the number of forward kanbans to be described later is acquired via S16 (S105). It should be noted that the kanban reduction number L is L = L0 when there is no forward kanban. Also, if there is a kanban to be moved forward, L = L0 + Sn (n =
1, 2,...). However, if the number of kanbans is reduced P based on the production plan, L0 = P / (C + 1), S
n is the number of kanbans moved forward.

The comparing unit 20c calculates the extraordinary kanban Xi recognized in S100 and the kanban reduction number L acquired in S105.
Then, using the lower limit number M determined in S103, it is determined whether or not the kanban can be reduced without falling below the lower limit number M (S106). If (Xi-L) ≧ M,
Since the number of sheets does not fall below the lower limit number even if the reduction adjustment is performed, the number correction unit 20d performs the reduction adjustment of the kanban reduction number L (S10).
7). That is, the number of kanbans is corrected to (Xi-L),
The number of kanbans for the delivery instruction flight i is provided to the delivery instruction unit 22, and a series of changes in the lower limit number and the processing of the delivery instruction are completed. For example, in the delivery instruction based on the out-of-order kanban X3, even if the reduction of the kanban reduction number L is performed, the delivery instruction number exceeds the lower limit number M, so that the number can be adjusted, and the number correction unit 20d outputs the kanban number a3.

On the other hand, if (Xi-L) <M, the decrease adjustment will result in a value lower than the lower limit number.
d modifies the number of kanbans to (Xi-M) (S10
8) The delivery instruction unit 22 is provided with the number of kanbans for the delivery instruction flight i as (Xi-M). At this time, S = L−
(Xi-M) kanban number data is increased / decreased T
It is supplied to the BL 16 and added to the kanban reduction number L for the next delivery instruction flight (i + 1) to make L = L0 + Sn (S109). Then, the process of changing the lower limit number and delivering instruction is completed.

For example, in FIG.
In the case of the processing for, if the number L is subtracted from the outlying kanban X2, it falls below the lower limit number M. In this case, the number correcting section 20d outputs the kanban number a2 (= M) in which the shortage S1 = L− (X2-M) is moved forward. Then, the shortfall S1 is carried over to the processing for the missing kanban X1,
Kanban reduction number L = L0 + S for outlying kanban X1
Let it be 1. Similarly, in the process for the outlying kanban X1, the lower limit number M is set as S2 = (L0 + S1)-(X
1 -M) occurs. Also in this case, the kanban is brought forward in the same manner as described above.

By the way, the kanban which deviates next to the deviated kanban X1 is the deviated kanban Y1 which occurs first after the production plan reduction adjustment. That is, in S101 of FIG.
> T, the lower limit is M = K (n + 1) / (C +
1) The lower limit number M is defined by xs / 100 and is linked to the set number of rotations K of the kanban in accordance with the reduction of the component consumption based on the production plan. At the same time, because the reduction adjustment of the sign on the basis of the production plan has been completed, reducing the adjustment against the Y1 is only ahead of schedule amount. Therefore, even if the previously moved shortage S2 is subtracted from the off-track kanban Y1, the number M does not often fall below the lower limit number M. If the amount of missed kanbans Y1 is less than the lower limit number M even if the amount is less than the lower limit number M, the lower limit number is adjusted so that the amount of the outer kanbans will not permanently fall below the lower limit number M from the next time onward. Immediately converges, and the number of delivery instructions follows the number of outlying kanbans.

As described above, the lower limit number of sheets is automatically corrected in conjunction with the fluctuation of the production plan, for example, the set number of rotations Kn, K (n + 1) which fluctuates based on the production plan every month or every year. Delivery instructions can be reduced.

In the above-described embodiment, an example in which the lower limit number is changed in accordance with the set number of rotations of the kanban has been described. The following is an example in which the lower limit number is changed based on the actual consumption of the parts (the actual performance of the kanban). explain.

The flowchart shown in FIG. 4 is a part for determining the lower limit number M corresponding to S100 to S104 in the flowchart of FIG. First, the reading unit 20a of the kanban processing unit 20 determines a delivery instruction flight i for performing a delivery instruction based on the extraordinary kanban Xi recognized by the reader 14 based on the delay coefficient C (S200). Then, the reading unit 20a extracts m (for example, recent 5) missed Kanban results recently read by the reader 14 (S20).
1). Subsequently, f (for example, four) are selected from the m pieces of results extracted from the one with the smaller number of outliers (S2).
02). Further, the lower limit number changing unit 20b calculates an average value for the selected f cases, and based on the average value, determines the lower limit number M
= (Sum of selected f cases) / f × (s / 100) is calculated (S203), and the lower limit number M is determined (S204). Here, s is the above-mentioned safety coefficient. After the determination of the lower limit number M, the same processing as S105 and subsequent steps in the flowchart of FIG.

As described above, by changing the lower limit number M on the basis of the actual kanban results, even if the component consumption is reduced due to some trouble, the lower limit number M changes according to the change. Processing can be reduced.

FIGS. 5 and 6 show the transition of the lower limit number M which changes in accordance with the change in the number of out-of-order kanbans. FIG.
M1 is the transition of the lower limit number when m = 5, f = 4, and M2 is the transition of the lower limit number when m = 5, f = 2. In this way, the lower limit number is changed so as to follow the change in the number of kanbans. At this time, the followability of the lower limit number of sheets to the fluctuation of the outlying kanban depends on the selected number f.
For example, when out-of-order kanbans occur on average as shown in FIG. 5, the smaller the number of selections f is, the better the followability of the lower limit number is, and the amount of forward kanbans is reduced.

On the other hand, as shown in FIG. 6 (a), when a state occurs in which the noise is extremely low and the number of kanbans is small, the influence of the noise is less as the selection number f is larger. In addition, as shown in FIG. 6B, in a case where a state in which the number of kanbans is extremely large in terms of noise occurs, the influence of the noise is less as the value of (m−f) is larger.

As described above, when the lower limit number is changed based on the results of the outlying kanban, it is desirable to determine the selection number f in consideration of the noise generation tendency and the like.

In this embodiment, an example in which the lower limit number is changed based on the set number of rotations and the actual number of missed kanbans has been described. However, the lower limit number is changed centering on the delay coefficient C of the kanban cycle, the production plan change date, and the like. May be performed.

In this embodiment, the so-called link kanban system in which kanban actually circulates between a parts factory and a production factory has been described as an example. By transmitting and receiving the data, the present invention can also be applied to a so-called electronic kanban system in which a delivery instruction is issued.

[0035]

As described above, according to the present invention,
The lower limit number of sheets is automatically changed by linking to fluctuations in parts consumption, and it is possible to reduce the number of delivery timing instruction cards for each delivery flight, reducing the number of advance delivery instructions. Unnecessary inventory can be eliminated.

[Brief description of the drawings]

FIG. 1 is a block diagram showing the overall configuration of a system of a management apparatus for a delivery timing instruction card according to the present invention.

FIG. 2 is a flowchart illustrating a procedure for changing a lower limit number of sheets and providing a delivery instruction in the management apparatus for a delivery timing instruction card according to the present invention.

FIG. 3 is a schematic diagram illustrating the transition of the lower limit number of sheets and the advance of the delivery timing instruction card in the management apparatus of the delivery timing instruction card according to the present invention.

FIG. 4 is a partial flowchart illustrating another determination procedure of the lower limit number in the management apparatus for the delivery timing instruction card according to the present invention.

FIG. 5 is a schematic diagram for explaining the transition of the outlying kanban and the lower limit number of sheets in the management apparatus of the delivery timing instruction card according to the present invention.

FIG. 6 is a schematic diagram illustrating another transition of the outlying kanban and the lower limit number of sheets in the delivery timing instruction card management device according to the present invention.

FIG. 7 is a schematic diagram for explaining the transition of the lower limit number of sheets and the advancement of the delivery timing instruction card in the conventional delivery timing instruction card management device.

[Explanation of symbols]

10 management device, 12 kanban (delivery timing instruction card), 14 reader, 16 increase / decrease adjustment TBL, 18
Lower limit setting TBL, 20 Kanban processing unit, 20a reading unit, 20b Lower limit number changing unit, 20c comparing unit, 2
0d Quantity correction section, 22 Delivery instruction section, M lower limit number of sheets.

────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Takeshi Fukuyama 1 Toyota Town, Toyota City, Aichi Prefecture Inside Toyota Motor Corporation (56) References JP-A-3-142668 (JP, A) JP-A-3-198152 (JP, A) (58) Field surveyed (Int. Cl. ⁷ , DB name) G05B 19/418 G06F 17/60 108

Claims (3)

(57) [Claims] 1. A delivery timing instruction card management device for instructing, at a predetermined timing, between a parts consumer and a parts supplier to deliver parts consumed by the parts consumer, based on a result of parts consumption. Recognition means for recognizing the number of delivery timing instruction cards to be presented to the component supplier by means of a component, and lower limit number changing means for changing the minimum number of delivery timing instruction cards that can be presented to the component supplier according to component consumption conditions when, a comparing means for comparing the minimum number and the presentation number, the result of the comparison, if the presentation number was less than the minimum number, the match with the minimum number to add the difference to the presentation number, the difference The parts consumption at the next delivery instruction
A delivery timing instruction card management device, comprising: a number correction means for performing correction by subtracting from the number of presentations based on actual results . 2. The delivery timing instruction card management device according to claim 1, wherein said lower limit number changing means changes a minimum number according to a total number of delivery timing instruction cards based on a production plan. Instruction card management device. 3. The management apparatus for a delivery timing instruction card according to claim 1, wherein said lower limit number changing means includes an extracting means for extracting a predetermined number of low consumption results from recent consumption results, and A management device for a delivery timing instruction card, wherein the minimum number of sheets is changed based on actual results.