JP4040608B2 - Decision support system in contract filling production - Google Patents

Description

  The present invention relates to a decision support system for manufacturing personnel in contract manufacturing related to filling and commercialization, and in particular, a client involved in contract manufacturing in the beverage industry (hereinafter referred to as a brand owner in accordance with the practice of the beverage industry). And systems that support decision-making by partner companies.

  In pharmaceuticals, cosmetics, beverages and the like, a manufacturing form called contract filling production is generally performed. For products made by filling, the brand owner who has sales rights makes a request for a quotation review to a supplier with production equipment called a packer, and the packer produces a packer by summarizing a quotation review request from various brand owners every month. This is a form in which a production plan that can be made by the equipment is presented, an order is determined according to the content, and the production is performed.

(Production planning)
Here, the manufacturing plan is performed by the packer upon request from the brand owner, and moreover, it is intended to have multiple brand owners competing with each other as customers. Information cannot be obtained from the brand owner. The production plan here is different from the production plan based on such prediction.

(Manufacturing plan)
The production plan described in the present invention is a list of the production volume and start time calculated based on the brand owner's estimate request and the capacity of the production facility of the packer. It is used to make decisions such as confirmation and change.

(Manual planning)
Conventionally, in the contract manufacturing industry, decision making related to manufacturing was made with reference to the manufacturing plan created manually, but it took several days to collect the estimate review request and create the manufacturing plan, It was difficult to present manufacturing plans in a timely manner in response to changes in orders from the market and brand owners that change in a short cycle.

(Planning takes a few days)
Especially in the beverage industry, it is normal for order changes to occur frequently in response to the changing market, but it takes several days to create a production plan that reflects the changes. However, there was a problem that the manufacturing plan could not be fully utilized for decision making in order to cope with the order change.

(Requires specialist)
Furthermore, because the manufacturing equipment and products that are subject to the manufacturing plan are not uniform, a specific product can only be manufactured using a specific manufacturing facility, or a specific product is followed by another specific product. There is a special restriction that cannot be made, and there is a problem that a production plan cannot be created correctly unless it is an expert who is familiar with the restrictions unique to such products and production facilities.

(Problems of various viewers)
In consignment filling, there are many cases in which there is a competitive relationship among commodities described in the production plan, and it is difficult for the parties concerned to browse as they are. Also, depending on the viewer's position, there are various cases where it is desirable to display the unit of manufacture on a pallet, or to desire a carton unit. It has been desired to change the display form and display range according to the authority and desire of the viewer.

  Every time an order from a brand owner or a change is received, the production plan creation procedure is repeated within the shortest 24 hours, and a production plan corresponding to the daily change is repeatedly generated to match the constraints and orders of the manufacturing equipment. The latest production plan can be repeatedly presented until the brand owner is satisfied, and the generated production plan is displayed in the form according to the authority of the viewer and as needed to support decision making regarding the production. I will provide a.

The decision support system according to claim 1 of the present application is:
In response to an estimate review request including ordering requirements that include production items, total number of orders, number of divided production lots, and desired delivery date for divided production lots from multiple requesters, reply to the production plan, and the agreement of the clients In the contract manufacturing of filling products to receive orders,
1) a sales department input / output terminal (1001) for inputting the order requirement;
2) a master management module (1006) including at least a product master (10003) and a manufacturing condition master (10004);
3) The order requirement from the sales department input / output terminal (1001) is input, the priority line registered in the product master (10003) managed by the master management module (1006) is searched, and each divided line is searched. An order processing module (1002) for automatically assigning a production lot to the priority line according to the desired delivery date of the divided production lot;
4) For the production lot of the priority line registered by the order processing module (1002), the production condition of the priority line is input from the production condition master (10004), the production time is automatically calculated, and the production plan is determined. A production planning module (1005) to simulate;
5) A manufacturing plan browsing module (1007) for presenting the manufacturing plan in a display form corresponding to the attribute of the viewer;
With
The order processing module (1002) inputs the manufacturing plan created by the manufacturing plan creation module (1005), outputs the manufacturing plan for the estimate review request to the manufacturing plan browsing module (1007), and the original manufacturing. If there is a change in the plan, the change is warned or the change is stopped.

The decision support system according to claim 2 of the present application is:
The product master (10003) is characterized in that if there is a difference in manufacturing requirements, even if the manufactured item is the same, the product master is further divided and has a structure capable of specifying a product.

The decision support system according to claim 3 of the present application is:
When the order processing module (1002) receives a new order, a product item that can be selected from the product master (10003) using the code of the sales representative or brand owner acquired from the sales department input / output terminal (1001) as a key. Display and compare the total number of orders received from the sales department input / output terminal (1001) with the total number of split productions entered by the sales staff, and warn if there is a difference of a certain value or more When changing orders, compare the actual production quantity obtained from the information management system at the manufacturing site with the changed total order quantity, and register if the total order quantity is less than the actual production quantity. It is comprised so that it may stop.

The decision support system according to claim 4 of the present application is:
The production condition master (10004) stores production conditions including at least the container filling speed of the production line, the container change standard time, the product switching cleaning standard time, and the number of batches that can be continuously produced.
The manufacturing plan creation module makes an inquiry to the master management module, acquires the manufacturing conditions from the manufacturing condition master (10004), sets the number of batches that can be continuously produced in each manufacturing line to the manufacturing plan of the priority line, The divisional production lots of the request for quotation are set in the production plan of the priority line in the desired delivery date of the request for quotation, and the production time is calculated based on the information on the container filling speed.

The decision support system according to claim 5 of the present application is:
The production plan creation module (1005) compares the total number of orders received in the estimate review request with the total number of divided production lots after the change when an order is changed, and notifies a warning of a contradiction in quantity.

The decision support system according to claim 6 of the present application is:
The master management module (1006) includes a production rule master (10005) that describes at least prohibition conditions related to the production order.
The production plan creation module refers to a prohibition condition of the production rule master (10005) when creating a production plan, and issues a warning notification of a setting corresponding to the prohibition condition.

The decision support system according to claim 7 of the present application is:
The order processing module (1002) is characterized in that when there is a change in an order, and there is a change in a divided manufacturing lot set before the change, the divided manufacturing lot is notified of a warning or the order change is stopped. To do.

The decision support system according to claim 7 of the present application is:
The manufacturing condition master includes a composition of raw materials, a packaging material, a manufacturing line, a manufacturing speed, a quantity per batch, and a sterilization schedule pattern by sanitation.

  In a form that matches the partner who presents the generated manufacturing plan by generating a manufacturing plan at the level of several hours in response to a request for an estimate review from a brand owner that changes daily due to changes in the market, etc. By having you browse, there is an effect that the decision-making regarding manufacture can be made at a good timing.

  Hereinafter, an embodiment in which the present invention is applied to the beverage industry will be described as an example.

(overall structure)
FIG. 1 is a schematic configuration diagram of a decision making system according to the present invention.
Sales department input / output terminal 1001, order processing module 1002, manufacturing plan storage module 1003, process department input / output terminal 1004, manufacturing plan creation module 1005, master management module 1006 that stores masters such as types and manufacturing conditions of manufacturing items and manufacturing lines The browsing module 1007 is configured.

  The sales department input / output terminal 1001 is a personal computer connected to the order processing module 1002 via an in-house LAN in which security is ensured. A predetermined input is made to the order processing module 1002, the order processing module is operated, and initial condition settings for manufacturing plan simulation are registered in the manufacturing plan storage module 1003. Based on the registered initial conditions and various manufacturing condition masters stored in the master management module 1006, a production plan simulation by the manufacturing plan creation module 1005 is performed by an operation from the process department input / output terminal 1004. The result of the simulation is used by a brand owner or a manufacturer related to manufacturing to browse and form a decision making or agreement related to manufacturing in a manufacturing plan browsing module composed of browser terminals connected to the Internet.

(Order processing)
FIG. 2 is a flowchart showing the operation of the order processing module 1002.
Upon receiving an estimate review request from the brand owner, the sales representative needs to extract the order requirement from the estimate review request and register it as an initial condition that can be machine processed. Conventionally, this is an operation in which a salesperson interprets an estimate review request based on his own knowledge and experience and inputs it.

  In the order requirement registration start step S201, the sales representative inputs his / her code. FIG. 3 shows an example of the initial screen. Here, the person-in-charge code 3001 is input. However, a customer code 3002 for designating a brand owner may be input.

  In the product master selection step S202, the product master of the latest generation manufactured item is displayed using the code of the brand owner or sales representative as a key. The sales representative can select the exact manufacturing items necessary for manufacturing simply by selecting from the displayed options. FIG. 4 is a product master selection screen output to the sales department input / output terminal. Designation of the items included in the brand owner's quotation review request is often ambiguous and may not be accurate to meet manufacturing requirements, but it is manufactured by selecting from product masters that are finely classified according to manufacturing requirements. The entry of items is simplified and the designated entry is made quicker. Reference numeral 4001 denotes a list of product masters. Here, as shown by 4003, the latest version of the product master is preferentially displayed. Furthermore, what is handled as “product 1” in a lump for the brand owner is classified into four product masters as indicated by reference numeral 4002 depending on the manufacturing conditions.

  In the total number of orders received and divided production lot input step S203, the total number of orders received and the quantity of the divided production lots to satisfy the total number of orders and the desired delivery date are input. FIG. 5 is an example of an input screen for the total number of orders 5001 and the divided production lot 5002.

  In step S204 for checking the total number of orders and divided manufacturing lots, it is checked whether the difference between the total quantity of each divided manufacturing lot and the total number of orders is within a preset range. The display screen is notified. Although this is a warning notification, a method of locking the progress of input may be used.

  Next, in the automatic line selection step S205, the priority lines registered in the product master are referred to, and the divided production lots are automatically assigned to the production lines according to the desired delivery date. FIG. 6 is a screen displaying manufacturing lines (hereinafter referred to as priority lines) to be preferentially selected set as product masters managed by the master management module 1006. Here, a priority line 6001 is set for “Product 1 U tack” of Company A. The configuration of the master management module will be described in detail later. Conventionally, the suitability information of the production line, which is different for each production item, is selected based on the knowledge and experience of the person in charge in the process department, and it takes time to select the production line and assign the production lot. Here, the part that relied on this craftsman's knowledge and experience has the effect of being automated.

  FIG. 7 is a flowchart showing the order change operation of the order processing module. In the order change registration start step S701, the sales representative inputs his / her code. Although the person-in-charge code is input here, a method of inputting a customer code for designating the brand owner may be used.

  In the change target order selection step S702, the target order information is called, and in the order total / divided manufacturing lot change step S703, the quantity and the desired delivery date are changed.

  Next, in step S704 for checking the total number of orders received and the quantity of divided lots, a check is performed to determine whether the difference between the total quantity of each divided production lot and the total number of orders is within a preset range. If a warning message is displayed, Although this is a warning notification, a method of locking the progress of input may be used.

  In the actual quantity check step S705, an inconsistency between the quantity of the modified divided manufacturing lot and the actual quantity at the time of order change is checked. Here, as a result of correction of the production lot, it is not allowed that the total number of orders is less than the actual production number, and if inconsistency occurs, the warning notification or the progress of change input is locked. The actual quantity is obtained from the order processing module by accessing the information management system at the manufacturing site via a communication line such as an in-house LAN or WAN.

  In the automatic line selection step S706, the priority lines registered in the product master are referred to, and the divided production lots are automatically assigned to the production lines according to the desired delivery date.

(Manufacturing plan simulation)
The process department input / output terminal 1004 is a personal computer connected to the production plan creation module 1005 via an in-house LAN in which security is ensured. The person in charge of the process department operates the manufacturing plan creation module 1005 from this personal computer, and refers to the initial conditions registered in the manufacturing plan storage module 1003 and the master related to the manufacturing conditions stored in the master management module 1006, thereby manufacturing the manufacturing plan. Perform a simulation. Since the production plan creation module 1005 requires high load calculation and speed, it is desirable that the production plan creation module 1005 is composed of a large computer with high processing capability.

  The manufacturing plan simulation operation of the manufacturing plan creation module will be described with reference to the flowchart of FIG. In the standard operation time setting step S801, a regular inspection period and a standard operation time are set for each production line by a simple method.

  Next, in the production lot delivery date automatic arrangement step S802, the priority lines set for each production item are referred to as illustrated in FIG. 6, and the divided production lots are distributed by priority lines in the desired delivery date set in the order processing. .

  Previously, the work of distributing divided production lots to each line was performed based on the knowledge and experience of the person in charge of the process. In addition to preventing mistakes, it enables faster production planning simulations.

  In the production time automatic load detection step S803, the production time is automatically calculated for each line based on various standards set in the production line and product master managed by the master management module 1006. Standards used here include container filling standard speed, container change standard time, product changeover cleaning standard time, number of batches that can be produced continuously, and washing time pattern after continuous production. It is registered as.

  By setting detailed standards and associating them with products and production lines, it is possible to simulate an accurate production plan simply by specifying the exact production items and split production lots (quantity and production order). is there.

  If the load of each production line is balanced as a result of simulating the production plan in step S803, does each production lot meet the desired delivery date? Perform the check. If not balanced here, the process proceeds to step S804.

  In line movement change step S804, the person in charge of the process department changes the production lot from a line with a heavy load to a production plan for another line while referring to the load of each line calculated in step S803.

  Next, in the prohibition condition check step S805, planning that significantly impedes production is prevented. Prepare manufacturing rule master in advance, set prohibition conditions, stop warning and planning. An example of the prohibition condition is prohibition of a setting that affects the quality of the product, such as switching from a strong fragrance product such as coffee to an alkaline ionized water having no flavor.

  In order change warning step S806, in order to ensure that the order change is immediately and quickly reflected in the line-by-line manufacturing plan simulation, a warning notification is issued on the simulation screen for the production lot in which the order change has occurred, the corresponding production lot is deleted, and the production is performed again. The simulation cannot proceed until the settings are registered in the lot production plan, and the progress is locked.

  When steps S805 and S806 are cleared, the process returns to step S803, and the production plan is simulated again under the initial conditions reflecting the line change. And if the load between each line is balanced, whether each production lot meets the desired delivery date? Judgment is made. If there is no problem here, the manufacturing plan simulation is once ended, stored in the manufacturing plan storage module 1003, and can be browsed by the brand owner and the manufacturing related parties via the browsing means 1007.

  As a result of browsing, if there is a production lot that does not satisfy the desired delivery date, for example, the brand owner is not satisfied, the production order set here as the production plan initial condition is changed in the production order change step S807.

  FIG. 9 shows the terminal screen. As shown in 9001, the number 0 is placed at the end of the sequence number (SEQ) of the production lot, and a space for inserting 1 to 9 production lots is secured from the beginning so that the production order can be changed easily. Is set in advance. The “change” displayed in the production lot of SEQ = 0130 shown in 9002 of this screen is a warning display indicating the lot whose order has been changed.

  By making the change settings simple and simple, the burden on the person in charge by repeating the simulation at high speed is reduced, and a flexible manufacturing plan is made possible.

(Master)
Here, a master that has been used in several steps in order processing and manufacturing plan creation processing will be described. FIG. 10 shows the configuration of the master management module 1006. It is connected to an order processing module and a manufacturing plan creation module via an in-house LAN 10001, and the access control means 10002 receives an inquiry for order processing and manufacturing plan creation, and searches for and transmits necessary master information. 10003 to 10007 are examples of master groups managed here. Here, a product master 10003, a manufacturing condition master 10004, and a manufacturing rule master 10005 are included. Here, each is illustrated as a single master database, but the configuration of the master management module of the present embodiment is not limited to this, and the composition of raw materials, packaging materials, and production lines necessary for creating a production plan are not limited thereto. , Production rate, yield per batch, pattern of sterilization schedule by sanitation, mold change time associated with switching of production items, etc. There may be.

  The description of the product master 10003 is supplemented. An important item to be managed by the product master is the manufactured item. It is a prerequisite to specify the correct manufacturing item for manufacturing. However, the information included in the estimate review request from the brand owner is often vague, and there are also categories that do not exist in the brand owner's product category, such as products with stickers attached in a soft drink campaign or the like. The product master 10003 covers manufactured items that are divided into detailed categories that reflect such manufacturing differences, and the sales representative only selects the displayed product item master as shown in FIG. You can specify the detailed classification required for manufacturing.

  In addition, as shown in FIG. 6, the production master 10003 is set as a line information on a production line that is preferentially distributed for each production item and a manufacturable line that can handle the production. By referring to such a product master, there is an effect of automating production line setting in order processing and preventing errors.

  Production condition masters 10004 related to production such as products and production lines include masters such as a container filling standard speed, a container change standard time, a product switching washing standard time, the number of batches that can be continuously produced, and a washing time pattern after continuous production. By referring to these as standards as masters, the load on the production line can be simulated accurately and at high speed.

  The production rule master 10005 masters the above-mentioned prohibition conditions that significantly impede production, such as the prohibition of settings that affect the quality of products, such as switching from strong flavored products such as coffee to tea with less flavor. It is said.

(Browsing module)
FIG. 11 is a diagram illustrating an example of the configuration of the browsing module 1007.
PC 11001 with browser function and communication means for Internet connection, mobile phone 11002 with browser function that can be connected to the Internet via a packet network of communication carrier, Internet 11003, web server 11004, saved in manufacturing plan storage module The configuration includes an application server 11005 that generates a display screen in response to a request for the manufactured manufacturing plan, an internal LAN 11006 that connects the manufacturing plan storage module and an in-house terminal, and a firewall 11007.

  The browsing module 1007 generates a drawing in a necessary format according to the attributes of the viewer who transmits the browsing request, and distributes the drawing to the browser terminal of the viewer (the personal computer 11001 or the mobile phone 11002).

FIG. 12 is an example of a display screen distributed to the brand owner.
Here, a screen when the brand owner A is a viewer is shown, and only the production plan of the company A is displayed according to the viewing authority. As shown in 12001, product 1 and product 2 of company A are displayed. If the person in charge of the process department of the consignment filling company has the authority to access everything like a viewer, a screen displaying the production lots of all brand owners can be viewed as shown in FIG. Here, the manufacturing plan of company B, which is not displayed in FIG. 12, is displayed between the manufacturing plan 13001 of product 1 of company A and the manufacturing plan 13002 of product 2.

  FIG. 14 is a weekly manufacturing plan display screen. Here, different browsing views due to differences in viewer attributes / privileges and browsing views in which the time axis is changed from a normal month to a week are shown as examples. However, the browsing view of the browsing module of the present invention is not limited to this. The view is not limited, and a view that is organized around manufacturing items, packaging materials, and other manufacturers, production lines, and types of raw materials may be adopted.

  Like the beverage industry, there are demand fluctuation factors that are difficult to predict, such as changes in the weather and fashion, and even the competing brand owners are customers, respecting their customers' decisions, and changing production schedules that occur frequently It is a system desired by the industry that must go in response.

Schematic configuration diagram of the decision making system of the present invention Flow chart showing the operation of the order processing module Initial screen output to the sales department I / O terminal Product master selection screen Completed screen for total number of orders and partial production lots Priority lines associated with product masters Flow chart showing order change operation Manufacturing plan simulation operation Manufacturing order change terminal screen Configuring the master management module Configuration of browsing module Browsing screen distributed to brand owners Browsing screen distrusted to the person in charge of the process department Weekly production plan display screen

Explanation of symbols

1001 Sales department input / output terminal 1002 Order processing module 1003 Manufacturing plan storage module 1004 Process department input / output terminal 1005 Manufacturing plan creation module 1006 Master management module 1007 Viewing module

Claims (8)

In response to an estimate review request that includes order requirements that include production items, total number of orders, number of divided production lots, and desired delivery date for divided production lots from multiple requesters, reply to the production plan and agree with the client In the contract manufacturing of filling products to receive orders,
1) a sales department input / output terminal (1001) for inputting the order requirement;
2) a master management module (1006) including at least a product master (10003) and a manufacturing condition master (10004);
3) The order requirement from the sales department input / output terminal (1001) is input, the priority line registered in the product master (10003) managed by the master management module (1006) is searched, and each divided line is searched. An order processing module (1002) for automatically assigning a production lot to the priority line according to the desired delivery date of the divided production lot;
4) For the production lot of the priority line registered by the order processing module (1002), the production condition of the priority line is input from the production condition master (10004), the production time is automatically calculated, and the production plan is determined. A production plan creation module (1005) to simulate;
5) A manufacturing plan browsing module (1007) for presenting the manufacturing plan in a display form corresponding to the attribute of the viewer;
The order processing module (1002) includes the manufacturing plan creation module (100
5) Enter the production plan created in step 5), output the production plan for the estimate review request to the production plan browsing module (1007), and warn the change if the original production plan is changed, or A decision support system characterized by stopping changes.   The will according to claim 1, wherein the product master (10003) has a structure in which, if there is a difference in manufacturing requirements, even if the manufactured items are the same, the product master can be specified in detail. Decision support system.   When receiving a new order, the order processing module (1002) selects a product item that can be selected from the product master (10003) using the code of the salesperson or brand owner acquired from the sales department input / output terminal (1001) as a key. Display and compare the total number of orders received from the sales department input / output terminal (1001) with the total number of split productions entered by the sales staff, and warn if there is a difference of a certain value or more When changing orders, compare the actual production quantity obtained from the information management system at the manufacturing site with the changed total order quantity, and register if the total order quantity is less than the actual production quantity. The decision support system according to claim 1, wherein the decision support system is configured to stop. The production condition master (10004) stores production conditions including at least the container filling speed of the production line, the container change standard time, the product switching cleaning standard time, and the number of batches that can be continuously produced.
The manufacturing plan creation module makes an inquiry to the master management module, acquires the manufacturing conditions from the manufacturing condition master (10004), sets the number of batches that can be continuously produced in each manufacturing line to the manufacturing plan of the priority line, The divided production lot of the request for quotation is set in the production plan of the priority line in the desired delivery date of the request for quotation, and the production time is calculated based on the information of the container filling speed. The decision support system described in any one.   The production plan creation module (1005) compares the total number of orders received in the estimate review request with the total number of divided production lots after the change when changing the order, and notifies a warning of a contradiction in quantity. The decision support system in any one of 1-4. The master management module (1006) includes a production rule master (10005) that describes at least prohibition conditions related to the production order.
The said manufacturing plan preparation module refers to the prohibition conditions of the said manufacturing rule master (10005), when creating a manufacturing plan, and notifies the setting which corresponds to the said prohibition conditions with a warning. The decision support system described in any one.   The order processing module (1002) is characterized in that when there is a change in an order, and there is a change in a divided manufacturing lot set before the change, the divided manufacturing lot is notified of a warning or the order change is stopped. The decision support system according to any one of claims 1 to 6.   The will according to any one of claims 1 to 7, wherein the manufacturing condition master includes a raw material composition, a packaging material, a manufacturing line, a manufacturing speed, a quantity per batch, and a pattern of a sterilization schedule by sanitation. Decision support system.

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