JP3480133B2 - 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 a delivery timing instruction card management device for delivering a predetermined number of parts in a production factory by a predetermined delivery flight, and in particular, increases or decreases the delivery instruction amount of parts as the production amount increases or decreases. Management of delivery timing instruction card at time.

[0002]

2. Description of the Related Art Conventionally, management of parts procurement has been an important element for improving the efficiency of product production management in factories. If the necessary parts are insufficient in the production process, the production cannot be performed, and therefore the parts must be out of stock as much as possible. On the other hand, having more parts than necessary in inventory is
It causes problems such as requiring extra inventory space.
Therefore, it is desirable to procure parts that satisfy both of these requirements, and that have a minimum inventory and that are not out of stock. Particularly in the case of a product produced by using a large number of parts such as automobiles, it is very important to efficiently procure the parts.

As such a parts procurement method, there is a procurement method called "Kanban" method. In this method, on the assumption that consumed parts are consumed again,
For example, a delivery timing instruction card (hereinafter referred to as kanban) is used to instruct delivery timing of a component that is instructed to be delivered to each component factory on a monthly basis based on the planned component usage amount. That is, a kanban delivered together with a part to a production plant (normally, the parts are packed in a box, and one kanban corresponds to one part box)
Removed from the parts box. Therefore, the Kanban Kanban is collected and put on the delivery instruction flight at a predetermined frequency, and the parts factory ( delivery instructions
Carry to indicate the destination). Here, as the delivery instruction flight, a return flight of a normal delivery flight is used. Then, the parts instructed to be delivered by this kanban are delivered from the parts factory to the production factory by delivery. This constitutes one Kanban cycle.

In this Kanban cycle, there are three variables a, b, and c that "a delivery instruction is given b times in a day, and the parts are delivered in a package after c flights counted from the delivery instruction". Will be decided by. Then, in such a kanban cycle abc, when the number of parts consumed per day is n, the number of kanban rotations (total number of circulating kanbans) N is expressed as follows. .

N = {n × (a / b) / m} × (c + 1 + k) Note that m is the number of accommodated components (the number of components accommodated in a component box corresponding to one kanban: number / component), k Is a safety factor and is for considering the number of kanbans required due to safety stock, transportation troubles during transportation, kanban collection intervals, and the like. In the following description, k = 0 is set for easy understanding.

Here, the first term on the right-hand side of the above equation corresponds to the average number of kanban missed sheets per flight. Also, although the delivery is delayed by c flights, the delay coefficient c is increased by +1 in consideration of the lead time from the time when the parts are delivered to the delivery site to the time when the parts are actually used.

In this way, by determining the number of kanban rotations N and repeating the delivery instruction / delivery, it is possible to automatically procure the necessary parts without missing parts.

However, the conditions for parts procurement may be changed. In this case, since there is a time lag between the delivery instruction and the delivery, some adjustment is required when changing. For example, Japanese Unexamined Patent Publication No. 5-89154 discloses a method of determining the number of rotations in anticipation of delivery date when it is necessary to increase or decrease the number of rotations of the kanban due to a change in the number of used parts. As a result, it is possible to eliminate the inconvenience caused by changing the number of used parts.

[0009]

However, the increase / decrease procurement of parts based on the change of the production amount of the production plan is usually the delivery issued based on the increase / decrease date determined on the basis of the assembly completion time (L / O day). Prepared by timing instruction card. Therefore, when parts are prepared for a product whose assembly cycle on the line is 6 hours, the parts used at the beginning of the line and the parts used at the end of the line are
There will be a time lag of about 6 hours before being consumed.
However, there are multiple deliveries per day (for example, every 2 hours).
In some cases, there is a problem that some parts will be treated as out-of-stock or will be treated as inventory.

Further, in the production line, the production plan may be delayed on an hourly basis due to various factors such as defective parts, repair work, and troubles in production equipment. Even if the production plan is delayed, the delivered parts are treated as inventory. On the contrary, if the production progresses faster than planned, there is a problem that parts may be out of stock.

The usage status of the parts and the progress status of the production in the line as described above cannot be judged from the production plan, and the careless increase / decrease adjustment of the delivery timing instruction card causes the parts to be out of stock or to be overstocked. However, it will not be possible to adequately manage parts procurement, which will lead to a decline in logistics efficiency.

The present invention has been made to solve the above problems, and when a delivery timing instruction card is used to instruct delivery of a component, the situation of consumption of the component in the production process is reflected and excess inventory and It is an object of the present invention to provide a delivery timing instruction card management device capable of issuing a delivery timing instruction card that accurately responds to the increase or decrease of parts without causing a shortage.

[0013]

In order to achieve such an object, the present invention provides an instruction to deliver a predetermined number of parts by a predetermined delivery flight based on a production plan including production amount increase / decrease information. A delivery timing instruction card management device for adjusting the issuance of a delivery timing instruction card,
And decrease calculation means for calculating the increment or decrement of the delivery timing instruction card number per flight based on the production volume increase or decrease, production
Shift to shift the issuance timing of the delivery timing instruction card that adds or subtracts the increase or decrease based on the component consumption information including the production progress information for the plan to the planned flight scheduled to be added based on the production plan A shift amount calculation means for calculating the amount, a number calculation means for calculating the number of delivery timing instruction cards for each flight based on the shift amount and the increase / decrease amount, and a delivery timing instruction card is issued according to the calculated number. And a card issuing means for performing the same.

According to this structure, the increase / decrease calculation unit calculates the increase / decrease in the number of delivery timing instruction cards per flight based on the increase / decrease in the production amount, and the shift amount calculation unit also operates.
Based on the consumption information of the parts including the production progress information for the production plan, calculate the shift amount between the delivery flight that actually adds the increase or decrease in the number of delivery timing instruction cards and the planned flight scheduled based on the production plan To do. Then, the number-of-sheets calculating unit calculates the number of delivery timing instruction cards for each flight based on the shift amount and the increase / decrease amount, and the card issuing unit issues the delivery timing instruction cards according to the calculated number. Therefore, the issuance timing of the delivery timing instruction card is shifted forward or backward with respect to the planned flight scheduled based on the production plan according to the consumption situation of the parts in the production process, and the delivery timing of the parts is corresponding to the shift amount. Therefore, it is possible to issue and manage a delivery timing instruction card capable of accurately increasing or decreasing the number of parts without excess inventory or shortage due to the consumption state of the parts.

According to another aspect of the invention, in the above structure, the shift amount calculating means calculates the shift amount based on component consumption information including information on a position where the component is consumed on the production line. Characterize.

[0016]

As described above , the shift amount calculating means calculates the shift amount based on the information on the position where the component is consumed on the production line and the component consumption information including the production progress information for the production plan, and the delivery timing instruction is given. Issue a card. Therefore, the issuance timing of the delivery timing instruction card is
According to the consumption situation of parts in the production process, it shifts back and forth for planned flights scheduled based on the production plan, and the delivery timing of parts shifts according to the shift amount, so the consumption status of parts changes Even in the case of carrying out, it is possible to issue and manage a delivery timing instruction card capable of accurately increasing or decreasing the number of parts without excess inventory or shortage.

According to another aspect of the invention, in the above structure, the shift amount calculating means reshifts the shift amount based on the consumption information of the parts one flight before when the increase of the number of delivery timing instruction cards is adjusted. It is characterized by including shift correction means.

According to this structure , the shift amount calculating means is
When the increase adjustment of the number of delivery timing instruction cards is performed, the number of delivery timing instruction cards is increased by one shift including shift correction means for re-shifting the shift amount based on the consumption information of the parts one flight before. Therefore, parts are always delivered before the start of increased production. For example, even if the production starts before the arrival of the first delivery flight of the increased production start date, the increased amount will be delivered on the last flight of the previous day, so that it is possible to reliably prevent the parts from being out of stock on the production line. Can issue and manage possible delivery timing instruction cards.

Further, in another invention, in the above constitution ,
The shift amount calculation means sets an upper limit value setting means for setting an increase upper limit value of the number of delivery timing instruction cards per flight, and sets the excess number as 1 when the number of delivery timing instruction cards exceeds the increase upper limit value. And an excess shift means for shifting before the flight.

According to this structure , the shift amount calculating means is
It has an upper limit setting means and sets an upper limit of increase in the number of delivery timing instruction cards per flight. When the increase in the number of delivery timing instruction cards exceeds the increase upper limit value, the excess shift means shifts the excess amount by one flight. Therefore, the increase in the number of delivery timing instruction cards per flight does not exceed the set value, and it is possible to prevent the increase adjustment of delivery timing instruction cards from concentrating on a specific flight. It is possible to securely prevent out-of-stock of parts, eliminate the bias of distribution instruction of parts and distribution load, and issue and manage a delivery timing instruction card that enables efficient distribution.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A preferred embodiment of the present invention will be described below with reference to the drawings. First, the increase / decrease adjustment of the delivery timing instruction card focusing on one arbitrary item (article number) will be described.

The delivery timing instruction card (hereinafter referred to as "Kanban") used in this embodiment is a delivery instruction destination (parts factory), delivery destination (production factory), product name, product number, parts procurement such as kanban cycle and number of accommodated parts. It is in the form of a sheet with all the information about it, and it circulates between the parts factory and the production factory. FIG. 1 is a block diagram for explaining the system configuration of the Kanban system, in which an automobile production factory 100 issues a parts delivery instruction to a parts factory 200, which is a supplier,
Parts factory 200 produces parts for which delivery is instructed
Deliver to.

The production factory 100 has a procurement processing device 10, and this procurement processing device 10 issues a kanban 12. Then, this kanban 12 is sent to the parts factory 200 as delivery instruction information indicating when and how many parts are to be delivered. In the present embodiment, this Kanban 12 is transmitted using a communication line, and
At 0, the Kanban is printed out. The parts factory 200 delivers the parts for which delivery is instructed, but at this time, the kanban 12 is also delivered. The delivered parts are consumed in the automobile manufacturing line 14, and by this consumption, the kanban 12 is removed from the parts box 16 in which the parts are housed, and as a result, the disengagement kanban occurs. Then, this detached kanban is read and supplied to the procurement processing device 10 as delivery instruction information. Since the procurement processing device 10 gives the delivery instruction at the optimum timing based on the detachment kanban, it can give the delivery instruction of the component based on the consumption of the component.

When parts are instructed to be delivered based on the detached kanban, that is, when the production quantity is stable, the consumed quantity is replenished, so there is no excess stock or shortage of parts. When adjusting the increase / decrease of the production amount based on the production plan, it is necessary to adjust the number and timing of issuance of kanban so that excess inventory or shortage of parts does not occur.

FIG. 2 is a system block diagram for explaining the processing sequence for adjusting the increase / decrease of kanban and the data flow together.

The use plan of parts by period (monthly) based on the production plan, for example, data such as the increase / decrease date of production and the set number of kanbans is keyed by the delivery instruction manager or the use plan is supplied from another production planning system. It is registered in the input processing unit 40. At this time, various data relating to the delivery instruction is provided and input from the databases to the usage plan input processing unit 40. For example, Kanban master D / B (database) 5
From 0, From-To information, that is, the main information (key information) of Kanban that shows which parts factory to deliver which parts factory, etc., and the number of parts delivered in one Kanban. Data such as the number of stored items and product names are provided. Also, the supplier master D / B 54 provides key information regarding the supplier (parts factory). In addition to this, a calendar D / B 56 that provides the calendar information necessary for date calculation when giving a delivery instruction, and an acceptance management D / B 58 that provides information such as the delivery destination of the part and the line number that uses the part, specified Flight cuts that provide data that there is no delivery on the date and time
The D / B 60 and the like are connected to the usage plan input processing unit 40.

Based on the information from each D / B and the information obtained from the production plan described above, the usage plan input processing section 40 sets the production plan based on the plan input record 52a of the increase / decrease adjustment D / B 52. Register the information of the increase / decrease delivery instruction flight (planned flight).

On the other hand, the increase / decrease registration processing unit 42 is provided with the information from the plan input record 52a. In addition, the increase / decrease registration processing unit 42 is provided with information regarding the detached kanban that has been removed from the line side (information regarding consumed parts).
With the delivery instruction D / B 62 and the above-mentioned D / Bs, namely, the Kanban master D / B 50, the supplier master D / B 54,
Calendar D / B 56, acceptance management D / B 58, flight cut D / B
60 is connected. In addition to this, information on the number of kanbans that are currently circulating is being managed.
A line management D / B 66 that provides information on the increase / decrease adjustment time based on the progress status of each production line is connected to the B 64. Based on these pieces of information, the increase / decrease registration processing unit 4
In step 2, the increase / decrease delivery instruction plan is calculated in consideration of the production progress status and the component consumption status for each line.

The flow of the increase / decrease adjustment processing in the increase / decrease registration processing unit 42 is performed in the order shown in the flowchart of FIG. The increase / decrease registration processing unit 42 calculates an increase / decrease amount calculation means 42a for calculating an increase / decrease amount of the number of kanbans per flight, and a delivery flight for actually adding the increase / decrease amount of a kanban from a planned flight scheduled based on the production plan. It includes a shift amount calculating means 42b for calculating a shift amount to be shifted, and a number calculating means 42c for calculating the number of kanbans for each flight based on the shift amount and the increase / decrease amount.

First, the increase / decrease calculation means 42a calculates the number of flights to be distributed based on the production plan and the kanban cycle (S11). In the case of the present embodiment, the number of delayed flights (c + 1) of the Kanban cycle is used as the number of flights to be sorted. Then, the kanbans for the increase and decrease are distributed evenly to this number of flights. As a result, the number of kanbans per flight during the increase / decrease adjustment period becomes equal to the number of kanbans per flight in the next period (next month), and a relatively smooth adjustment becomes possible. At this time, the increase / decrease average number of sheets per flight n can be calculated by the following equation, where S is the increase / decrease number of sheets of kanban.

N = S / (c + 1) However, when a kanban distribution cannot be performed uniformly because a fraction occurs in the average number n of increase / decrease, the increase / decrease amount calculating means 42
In step a, the preceding increased / decreased number is adjusted by adjusting the Kanban distribution before and after using the target tracking simple method.

Next, the number of kanbans currently circulating is subtracted from the number of kanban rotations set based on the increase / decrease plan to calculate the increased / decreased number of kanbans (S12). These data are sequentially added to the increase / decrease adjustment D / B 52. Then, the shift amount calculation means 42b determines the flight to start increasing / decreasing (S13). Basically, when the shift correction means included in the shift amount calculation means 42b makes an increase adjustment, it is determined that the adjusted delivery is started from the last flight on the day before the increase / decrease date, and in the case of a decrease adjustment, the increase / decrease is made. It may be decided that the adjusted delivery will start from the first flight on the day of the date, but in order to give more efficient delivery instructions, the data from the line management D / B 66 and the reception management D / B 58 should be used. Based on this, the increase / decrease start timing is calculated in consideration of the progress status of the manufacturing line, the usage status of parts in the line, etc., and the increase / decrease start flights in which excess or deficiency of parts do not occur are determined. In other words, the increase / decrease start flight is determined in consideration of the following items.

(A) Process depth of the target part (b) Production progress status Here, the process depth indicates at which position on the line the target part is consumed, for example, at the beginning of the line. Parts used are said to have a shallow process depth, and parts used at the end of the line are parts with a deep process depth. In particular, in a manufacturing line in which a line cycle takes several hours, the optimal delivery timing of a part is that the part is delivered when the part is actually consumed. Therefore, the process depth data for each part is registered in the Kanban master D / B 50, and the delivery instruction timing is changed according to the process depth from the planned flight determined based on the production plan when the increase / decrease start flight is determined. Shift to.

Further, the production progress status indicates a deviation before and after the time unit with respect to the production plan of the assembly work. When the assembly work is behind the plan, the parts delivered according to the production plan are overstocked, and when the assembly work is ahead of the plan, the parts are out of stock. Therefore, input the progress status of each line to the acceptance management D / B 58 and line management D / B 66 as the adjustment time, and adjust the progress from the planned flight determined based on the production plan when determining the increase / decrease start flight. To shift the delivery instruction timing back and forth. The shift amount Nb based on the progress status can be calculated by the following formula, where H is the adjustment time, b is the number of daily flights in the Kanban cycle, and T is the operating time of the line.

Nb = H / (T / b) Then, based on the above-mentioned results (increase / decrease number, average increase / decrease number, preceding increase / decrease number, distribution target flight, first adjustment number, start date / time flight based on shift amount, etc.) Then, the number-of-sheets calculating unit 42c calculates the number of kanban sheets for each flight and writes the number in the registration completion record 52b of the increase / decrease adjustment D / B 52 (S14). Then, when it is time to perform the delivery instruction increase / decrease adjustment, the increase / decrease adjustment start processing unit 44 starts the adjustment processing based on the data of the registration completion record 52b and sequentially registers the processing status in the adjustment-in-progress record 52c, while performing the adjustment processing. Based on, the kanban number management D / B 64 will be sequentially updated.

Further, the card issuing means 46a included in the increase / decrease adjustment processing unit 46 updates the information of the delivery instruction D / B 62 based on the data of the Kanban master 50 and the in-adjustment record 52c, and the increase / decrease processing is completed. No Kanban will be issued sequentially.

The increase / decrease adjustment processing will be described below using specific numerical values.

For example, it is assumed that 20 kanbans having a capacity of 10 and a kanban cycle abc = 1-8-4 are currently circulating. If it operates 16 hours a day, there will be deliveries every 2 hours. Now, according to the production plan, the production of a certain production line will increase from 200 units to 2 from 8/2 (Mon).
Suppose there is a plan to increase production to 70 units. First, in (S11) of the flowchart of FIG. 3, the number of flights to be sorted is 5 (c +
1 = 4 + 1 = 5) is calculated. The number of kanbans currently circulated is 20, and the number of kanban rotations set after the increase in production is calculated by the required number of parts / the number of accommodated parts, which is 27 (270
Since / 10 = 27), the number of increased / decreased kanbans is calculated as 7 (27-20 = 7) in (S12). Therefore, the average increase / decrease number per flight is n = S /
(C + 1) = 7/5 = 1.4. Also, 8/2
Since the production starts to increase from (Monday), the first adjusted delivery flight is shifted to the final flight on 7/30 (Friday), that is, the 8th flight on 7/30 by the shift correcting means (7/31).
(Saturday), 8/1 (Sunday) is a factory non-working day (holiday). Furthermore, if the process depth of the target component is a process two hours before the completion of the assembly, the adjusted delivery flight needs to be shifted one flight earlier depending on the process depth and delivered on the 7th flight of 7/30. On the other hand, if the assembly work on the manufacturing line is delayed by 4 hours from the production plan (delay is negative), the shift amount Nb based on the progress status is calculated as follows.

Nb = H / (T / b) = − 4 / (16/8) = − 2 In other words, due to the delay in the assembly work, the parts may be delivered two flights later, and the first adjustment 8 deliveries
It should be delivered on the first flight of / 2 (Mon). Therefore, the increase / decrease start delivery instruction flight is calculated backward from the Kanban cycle (delivery instruction 4 flights in advance) and becomes the 5th flight on 7/30 (Friday).

An explanatory diagram summarizing the above results is shown in FIG.

As described above, 1.4 kanbans are distributed to each flight. First of all, the average increase of 1.4 will be added to the 5th flight on July 30th, but based on the target tracking simple method, 0.6 (2-1.4 = 0.6) sheets will be advanced and actually 2 Kanbans are increased. Next, on the 6th flight, the average increase in the number of sheets added is 1.4 as well, but since the Kanban board was 0.6 sheets ahead on the 5th flight, the number of sheets sent out this time is 0.8 (1. 4-0.6 = 0.8) sheets. At this time as well, 0.2 sheets are advanced, and in fact, one sheet of kanban is added. Similarly, on the 7th flight, 1.2 sheets were sent out, and by the advance of 0.8 sheets, 2 sheets were actually increased, and 1 on 8th flight and 1 on 8/2 1st flight. Each is increased, and the increase / decrease adjustment is completed. After that, unless there is a change in the production amount, the instruction to deliver the parts is repeated according to the removal Kanban.

Although the case where the production is increased has been described in the present embodiment, similarly, when the production is decreased, the deconciliation start flights are calculated, the average number of reduced sheets per flight is calculated, and each flight is reduced. Calculate the reduced number of Kanban boards.

In the case where a cut flight whose delivery is cut from the start flight determined by the shift amount based on the process depth and the production progress status to the adjustment completed flight is registered in the flight cut D / B 60 The shift amount calculating means 42b calculates the shift amount so that the start flight is shifted forward by the number of cut flights.

As described above, when the parts are instructed to be delivered by kanban, the excess stock / out of stock is reflected by reflecting the consumption status of the parts in the production process, specifically, the progress status of the assembly work and the consumption position of the parts. It is possible to issue a kanban that accurately responds to the increase or decrease in the number of parts that does not occur.

Next, the increase / decrease adjustment of the delivery timing instruction card focusing on a plurality of items (for example, product number A to product number E) that can be delivered by the same delivery service will be described. Here, the product numbers A to E are parts that can be delivered by the same delivery service, but the number delivered by one Kanban,
In other words, the number of accommodations is different.

Similar to the above, there is a plan to increase production from August 2 (Monday).
Is one, product numbers C and D are two, and product number E is four. Then, as described above, it is assumed that, as a result of calculating the delivery start flight and the increased number of kanbans for each flight in consideration of the process depth, the production progress situation, etc. for each product number, the result is as shown in FIG. Since the product numbers A to E are parts that can be delivered by the same delivery service, if the delivery timing is instructed based on the increased / decreased number shown in FIG. It can be carried out.

By the way, when there are a plurality of parts that can be delivered by the same delivery service as in this embodiment, 7/30
Kanban increase will be concentrated on the 5th and 7th flights. As a result, the amount of parcels delivered may be uneven, which may lead to a reduction in physical distribution efficiency. Therefore, it is desirable to shift the Kanban increase / decrease timing.

In this case, the basic processing sequence for performing the kanban increase / decrease adjustment and the data flow are the same as those shown in FIG. 2, and the process flow in the increase / decrease registration processing unit 42 is also shown in FIG.
It is similar to the flow chart for one item shown in.
As shown in FIG. 6, in the case of processing for a plurality of items, first, as in the case of one item, the increase / decrease amount calculation means 42a.
Calculates the number of flights to be sorted for each item based on the production plan and kanban cycle (S21). Further, the number of kanbans currently circulating is subtracted from the number of kanban rotations set based on the increase / decrease plan for each item to calculate the increased / decreased number of kanbans (S22). Then, the shift amount calculating means 42b and the number-of-sheets calculating means 42c tentatively determine the number of flights to be increased / decreased and the number of kanbans to be distributed for each flight (S2).
3). That is, in (S21) to (S23), the same processing as in the case of one item is executed in parallel for a plurality of items to obtain the result of FIG. The increase / decrease start flights and the number of distributed kanbans for each flight tentatively determined in (S23) are corrected based on the total number of increased / decreased numbers for each flight according to the flowchart of FIG. 7 (S24), The corrected increase / decrease adjustment content is registered (S25).

The procedure for correcting the increase / decrease content (S24) will be described below with reference to the flowchart of FIG. 7 and the specific example of FIG. It should be noted that the correction of the increase / decrease content is executed by the shift amount calculating means 42b or the like (see FIG. 2) of the increase / decrease registration processing unit 42. Further, the shift amount calculating means 42b has an upper limit setting means for setting an increase upper limit value P of the number of kanban sheets per flight, and when the increased number of kanban sheets exceeds the increase upper limit value P, the excess number is set to 1 Includes excess shift means for shifting before the flight. The increase upper limit value P indicates the upper limit of the number of kanbans (total number of increased / decreased numbers M) that can be increased per flight, and the average increased / decreased number of kanbans due to increased production (n = S / (c + 1)), It is calculated by the product with the upper limit adjustment coefficient input to the increase / decrease registration processing unit 42 by the delivery instruction manager. Therefore, the delivery instruction manager can determine the upper limit of the Kanban increase by arbitrarily selecting the upper limit adjustment coefficient, and can select and manage the ordering timing, the material flow rate, and the like. In the case of the present embodiment, the increase upper limit P is 2 sheets / flight.

In (S23), once the increase / decrease start flight and the number of distributed kanbans for each flight are provisionally determined, the shift amount calculation means 42b (see FIG. 2) determines the total number M of the increased / decreased number of kanbans for each flight. It is calculated (S31), and the total number M of the increased / decreased number of each flight is compared with the increase upper limit P (S32). P < M
If there is a number of flights, the number of kanbans exceeding the increase upper limit P is focused on the flight closest to the increase / decrease date (8/2 in this embodiment) (7th flight on July 30). The minute is shifted by one flight before (S33). In this case, 7/3
The issue is which kanban to shift among 0 kanbans on the 7th flight, but select the part number with the largest number of kanbans due to increased production. This is because the number of parts affected by a single kanban is relatively small compared to the total increase in the item whose kanban increases in number.

In the case of the present embodiment, as shown in FIG. 8 (a), the flight closest to the increase / decrease date and exceeding the increase upper limit value P is the 7th flight on July 30, and the shift target is This is the Kanban of product number E, which has the largest increase in the number of sheets. As shown in FIG. 8B, this kanban is shifted to the kanban of the product number E on the 6th flight on 7/30, and the total number M of the increased / decreased number of each flight is updated (corrected) (S34). In other words, the total number M of the increase / decrease in the 7th flight on July 30 decreased to 2 and
The total number M of the 30th flight No. 6 increases and decreases to two. After updating the total number M of increased / decreased sheets, the processes of (S32) to (S34) are repeated until there are no flights corresponding to P < M. In the case of this embodiment, as shown in FIG.
Since the 5th flight on July 30 corresponds to P < M, the excess number of kanbans, that is, 3 kanbans, is shifted to the previous flight. At this time, as described above, for the item to be shifted one flight earlier, the item number with the largest number of kanbans due to the increase in production is selected in order, and thus the item number E, the item number D, and the item number C are selected in order, and
As shown in (c). As a result of the shift on the 5th flight on 7/30, the 4th flight on 7/30 corresponds to P < M, and therefore the kanban for the excess number of sheets is shifted in the same manner as described above. In this case, since the excess number is one, the Kanban of product number E is shifted to the front one flight, as shown in FIG. 8 (d).

At this point, there are no flights corresponding to P < M (S32), so the process of the flowchart of FIG. 7, that is, the correction of the increase / decrease contents (S24) is ended, and the result is used as the increase / decrease adjustment contents. The registration completion record 52b (see FIG. 2) of the D / B 52 is written (S25). Then, when it is time to perform the delivery instruction increase / decrease adjustment, the increase / decrease adjustment start processing unit 44 starts the adjustment processing based on the data of the registration completion record 52b and sequentially registers the processing status in the adjustment-in-progress record 52c, while performing the adjustment processing. Based on the above, the Kanban number management D / B will be sequentially updated.

Further, the card issuing means 46a included in the increase / decrease adjustment processing section 46 updates the information of the delivery instruction D / B 62 based on the data of the Kanban master 50 and the in-adjustment record 52c, and the increase / decrease processing is completed. No Kanban will be issued sequentially.

As described above, in addition to the adjustment based on the process depth of the target part and the progress status of the production, the increase status of the kanban for each flight is taken into consideration to reflect the consumption status of the parts in the production process and excess inventory. -It is possible to increase or decrease the number of parts accurately without causing out-of-stock items, stabilize the amount of luggage on each flight, and perform leveling in logistics, and realize efficient logistics. . That is, an extremely large number of parts are not delivered to the assembly plant by the same flight, and the delivered parts are efficiently and quickly transported to a predetermined place on the line side. Further, since the amount of instruction to be delivered is stable even for the parts factory to which the instruction to deliver the parts is given, it is possible to contribute to the leveling of production.

[Brief description of drawings]

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

FIG. 2 is a system block diagram for explaining together a processing sequence and a data flow of a delivery timing instruction card management device according to the present invention.

FIG. 3 is a flowchart showing processing in an increase / decrease registration processing unit of the delivery timing instruction card management device according to the present invention.

FIG. 4 is an explanatory diagram showing increase / decrease calculation of the number of kanbans in the delivery timing instruction card management device according to the present invention.

FIG. 5 is an explanatory diagram for explaining the result of increase / decrease in the number of kanban sheets for a plurality of items in the delivery timing instruction card management device according to the present invention.

FIG. 6 is a flowchart showing a process in the increase / decrease registration processing unit when the delivery timing instruction card management device according to the present invention processes a plurality of items.

FIG. 7 is a flowchart illustrating a procedure of correcting the increase / decrease content when the delivery timing instruction card management device according to the present invention processes a plurality of items.

FIG. 8 is an explanatory diagram for explaining an increase / decrease process of the number of kanban sheets when the management device for the delivery timing instruction card according to the present invention processes a plurality of items.

[Explanation of symbols]

10 Procurement processing equipment, 12 Kanban (delivery timing instruction card), 14 manufacturing line, 16 parts box, 40
Usage plan input processing unit, 42 Increase / decrease registration processing unit, 42a
Increase / decrease amount calculating means, 42b Shift amount calculating means, 42c
Number calculation means, 44 increase / decrease adjustment start processing section, 46 increase / decrease adjustment processing section, 46a card issuing means, 50 Kanban master D / B, 52 increase / decrease adjustment D / B, 54 supplier master
D / B, 58 Receipt management D / B, 62 Delivery instruction D / B, 64
Kanban number D / B, 66 line management D / B.

Continuation of the front page (56) Reference JP-A-2-292603 (JP, A) JP-A-5-89154 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) G05B 19 / 418 B23Q 41/08 G06F 17/60

Claims (4)

(57) [Claims] 1. A delivery timing instruction card management device for issuing and adjusting a delivery timing instruction card for instructing delivery of a predetermined number of parts by a predetermined delivery flight based on a production plan including increase / decrease information of production amount. Therefore, based on the increase / decrease calculation means for calculating the increase / decrease in the number of delivery timing instruction cards per flight based on the increase / decrease in the production volume, and the increase / decrease in the increase / decrease based on the consumption information of the parts including the production progress information for the production plan . Based on the shift amount and the increase / decrease amount, a shift amount calculation means for calculating the shift amount for shifting the issuance timing of the delivery timing instruction card for carrying out the addition to the planned flight scheduled to be added based on the production plan. And a delivery timing instruction according to the calculated number of delivery timing instruction cards for each flight. Management device delivery timing instruction card which comprises a card issuing means for issuing a over de, a. 2. The delivery timing instruction card management device according to claim 1, wherein the shift amount calculation means is based on component consumption information including information on a position where the shift amount is consumed on the production line. A delivery timing instruction card management device characterized by being calculated by In the management apparatus 3. A process according to claim 1 or claim 2 Symbol placement delivery timing instruction cards, the shift amount calculating means, the shift based on the consumption information of the component when performing increasing adjustment of the delivery timing indication card number A delivery timing instruction card management device comprising shift correction means for re-shifting the amount by one flight. 4. The delivery timing instruction card management device according to any one of claims 1 to 3 , wherein the shift amount calculation means determines the number of delivery timing instruction cards per flight. An upper limit value setting means for setting an upper limit value for increase, and an excess amount shift means for shifting the excess number of sheets by one flight before when the increase in the number of delivery timing instruction cards exceeds the increase upper limit value. A delivery timing instruction card management device.