JP4559698B2 - Supply and demand adjustment method and system, product manufacturing method - Google Patents

Description

【００９９】
式（１）の制約条件式は、「受注の引当数量の合計は、受注の要求数量に等しい」という制約条件を決定変数の一次式に表わしている。Ｃは受注がどの製造拠点で何時、幾つ引当されたかを表わす決定変数である。ｑは受注毎の要求変数（入力データ）である。一次式の左辺は、決定変数Ｃを全ての製造拠点ｆ、全ての時刻（τ，ｔ）について和をとった値で、計画期間内に引当てられた数量の合計値を表わす。この左辺の値が右辺の受注ｋの要求数量ｑに等しいというのがこの制約条件の意味である。このように受注引当計算に必要な全ての制約を一次式で記述する。
【０１００】
式（２）の目的関数では、複数の評価尺度が３つの重み付け係数α、β、γで組み合わされている。同式において、ＤＶは納期違反日数、ＰＨＣは在庫保有日数、ＥＤＣは前倒し／後倒し費用、ＰＣは製造費用、ＭＣは部材購入費用、ＰＭは生産平準化尺度である。
【０１０１】
重み付け係数α、β、γの値は、線形計画法の実行前に与える必要がある。重み付け係数αの値は、大きく設定すると、納期違反日数がなるべく小さくなるような引当結果が得られ、又、小さく設定すると、在庫保管日数や各費用がなるべく小さくなるような引当結果が得られる。
【０１０２】
なお、本発明は、上記一実施の形態に限定されるものでなく、実施段階ではその要旨を逸脱しない範囲で種々に変形することが可能である。
【０１０３】
さらに、上記実施形態には、種々の段階の発明が含まれており、開示されている複数の構成要件における適宜な組み合わせにより種々の発明が抽出できる。例えば、実施形態に示されている全構成要件から幾つかの構成要件が削除されても、発明が解決しようとする課題の欄で述べた課題が解決でき、発明の効果の欄で述べられている効果が得られる場合には、この構成要件が削除された構成が発明として抽出できる。
【０１０４】
【発明の効果】
以上詳記したように本発明によれば、生産の即時納期回答及び着工指示の作成が容易で、かつ納期遵守率、在庫保有日数及び生産負荷変動幅にそれぞれ無理のないような引当結果を導き出して経営ロスを削減できる需給調整方法及びそのシステム、製品の製造方法を提供できる。
【図面の簡単な説明】
【図１】本発明に係わる需給調整システムの一実施の形態を示すブロック構成図。
【図２】本発明に係わる需給調整システムの一実施の形態における引当処理を示す模式図。
【図３】本発明に係わる需給調整システムの一実施の形態における引当処理での部材調達状況の一例を示す模式図。
【図４】本発明に係わる需給調整システムの一実施の形態における前倒しと後倒しの一例を示す図。
【図５】従来の受注引当・着工指示作成方法を説明するための模式図。
【符号の説明】
１：注文データ部、２：部品在庫データ部、３：製造枠生成部、４：製造枠属性データ部、５：製造枠製造可能品目データ部、６：製造拠点属性データ部、７：製品基準データ部、８：製品在庫データ部、９：製品着工データ部、１０：製品着工データ生成部、１１：受注データ部、１２：最適化パラメータ部、１３：受注引当計算部、１４：需要予測データ部、１５：引当結果保持部。[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a supply and demand adjustment method for generating a start instruction for adjusting a supply of a product according to a demand such as an order from a customer while optimally maintaining, for example, the productivity of a manufacturing base and the stock quantity of a stock base, and its The present invention relates to a system and a product manufacturing method.
[Description of the rights of inventions achieved with federal research and development assistance]
  The achievements of at least some of the subject matter disclosed herein were partially subsidized by the federal government. The federal government may have certain rights with respect to the present invention.
[0002]
[Prior art]
For example, a manufacturer that performs assembly to order production, when an order for a product is received from a customer, an order allocation logic generally referred to as a seat reservation method is used to adjust supply and demand in order to promptly answer the delivery date and give a start instruction to the customer. Held in the system.
[0003]
In this seat reservation method, a manufacturable frame indicating when / how many products can be manufactured is calculated in advance in consideration of the production plan and the procurement status of parts, and the manufacturable frame is reserved in the order in which the order is received. Then, the delivery date of the product is answered based on the planned shipment date of the product. As a technique related to this seat reservation method, for example, there are Patent Documents 1 and 2.
[0004]
[Patent Document 1]
JP-A-4-145573
[0005]
[Patent Document 2]
JP-A-4-145574
[0006]
[Problems to be solved by the invention]
In the above-described order reservation / construction instruction creation method, the following provisions do not make good production possible for management. As the first provision, for example, the manufacturable allowance for the order item exists only where the desired delivery date can be satisfied due to the setting condition of the manufacturable allowance and the order receipt, and only allowance for delaying the delivery date is possible.
[0007]
The second allowance is that there is a manufacturable allowance for the order item only at a time much earlier than the desired delivery date. Can not.
[0008]
As the third provision, for example, there is no start of construction for this week's manufacturable allowance, and there is no start, but the next week's manufacturable allowance is fully reserved, and the production load fluctuation is busy next week. Provisions are made to increase
[0009]
The causes for each of the provision results are as follows.
[0010]
The reason for the first provision is to secure the production capacity regardless of what order orders will come in the future in order to allocate to the manufacturable allowance and product inventory every time an order is received and to answer the delivery date. I will do it.
[0011]
For example, as shown in FIG. 5, there are two orders # 1 and # 2 of the same item, and the delivery date of order # 2 is earlier than the delivery date of order # 1. If the allocation is made in the order of orders # 2 and # 1 according to the delivery time margin, the delivery date can be delayed by one day as shown in the allocation result “2”. However, since the inquiry for order # 1 is slightly earlier than order # 2, when order # 1 is allocated within the due date, order # 2 is forced to be delayed by four days as shown in the allocation result “1”. The
[0012]
If orders that have entered a certain period can be collectively allocated and if order # 1 and order # 2 can be allocated at the same time, order # 2 with an earlier delivery date is allocated first, and then order # 1 is allocated. . This can minimize delays in delivery.
[0013]
However, under the present circumstances, since the speed of answering the delivery date is emphasized, and the system responds to each order inquiry, the orders are assigned in the order of # 1 and # 2.
[0014]
The reason for the second allocation is that in the conventional seat reservation method, the manufacturable allowance set according to the production plan and the procurement status of parts is allocated to the set day or week, and other than the order of the item. The above problem arises because it cannot.
[0015]
However, in the stage where only common parts are actually ordered, there is no need to fix items, and multiple items can be manufactured, and delivery of parts can be accelerated or delayed depending on the ability of the component supplier Therefore, there is a case where the manufacturable frame can be used by moving around the set period.
[0016]
As a cause of the third allocation, a case will be considered in which the cause of the second allocation has been solved, and the manufacturable frame has been moved to some extent on the order delivery date. Due to the uneven delivery of orders, the delivery dates of several orders may be concentrated on the same day. For this reason, when the manufacturable frame is moved and completed in time for delivery, production concentrates on a specific day, and the fluctuation of the production load increases.
[0017]
Therefore, when calculating allowances, minimizing delays in delivery is the most important evaluation measure, but at the same time, measures such as product inventory days and production load leveling must also be considered. The reason for this is that if the delivery date of the order can be observed, there may be a case where an allocation result in which the production load is leveled is requested even if there is some product inventory until the delivery date.
[0018]
At present, the allocation process is performed based on the logic in accordance with the intentions of the person in charge of supply and demand. Therefore, the allocation is based only on a certain evaluation scale, and a plurality of evaluation scales cannot be reflected simultaneously.
[0019]
Such provisions do not cause good production in management, but cause management loss. The current situation is that manufacturers are carrying out production activities while acknowledging the management loss caused in this way. Therefore, manufacturers are taking measures to prevent management loss while maintaining operation of the supply and demand adjustment system. For example, while taking into account the order status, material procurement status, and production load status by human system, the production allowance is frequently changed so that it is easy to produce, and for example, order reservation and start-up are controlled so that it can be moved forward or backward Is going to do.
[0020]
Therefore, the present invention makes it easy to create an immediate delivery date reply and start instructions for production, and to derive a provisional result that is reasonable for the delivery date compliance rate, the number of days of inventory holding, and the production load fluctuation range, thereby reducing management loss. It is an object of the present invention to provide an adjustment method, a system therefor, and a product manufacturing method.
[0021]
[Means for Solving the Problems]
  The present invention relates to a supply and demand adjustment method that, upon receiving an order for a product, performs an allocation calculation according to at least a production plan and a procurement status of parts constituting the product, and outputs a delivery date and a start instruction for an order for the product. At least the number of products that can be manufactured in a given period at a manufacturing site based on at least part data, such as order data consisting of product items, required delivery date and quantity, and parts inventory data such as how many parts make up the product. The first process for generating the manufacturing frame attribute data and the manufacturing frame manufacturable item data to be displayed, the second process for holding the product inventory data indicating the product inventory, and the manufacturing base attribute data determined uniquely for the manufacturing base The third process that holds the product, and the number of manufacturing steps, lots, manufacturing lead time, shipping lead time, manufacturing line name, A fourth process that holds data such as material costs and the same product standard data for a plurality of manufacturing bases, a fifth process that holds product order data, and linear programming every time the order data is input A sixth step of performing an optimal allocation calculation;Sixth processA seventh step of holding the allocation result allocated bySixth processAn eighth step of generating product start data in a certain cycle from the allocation result allocated by the step, and deleting the production frame attribute data and the production frame manufacturable item data that are the product start data, respectively;Eighth processWhen the 9th process holding the product start data generated by the above and the order data input in the 4th process are allocated to product inventory data, product start data, manufacturing frame attribute data, and manufacturing frame manufacturable item data And a tenth process for holding optimization parameters such as constraint conditions and optimization priorities, and the sixth process includes manufacturing base attribute data, product reference data, , Refer to the optimization parameters and the allocation result, and target the product inventory so that all the order data that can be changed can be optimized within the range of constraints and optimization priority items. The supply and demand adjustment method is characterized by recalculating provisions for data, product start data, production frame attribute data, and production frame manufacturable item data.
[0026]
  The present invention, when receiving an order for a product, at least a production plan andConfigure the productCalculate the allowance according to the procurement status of parts,ProductIn the supply and demand adjustment system that outputs the delivery date and start instructions for orders,Order data part that holds order data consisting of at least product items, required delivery date, and quantity, parts inventory data part that holds parts inventory data such as how many parts make up the product, and regular orders Read the order data stored in the data section and the parts inventory data stored in the parts inventory data section, and at least how many products can be manufactured in a certain period based on these order data and parts inventory data. Manufacturing frame generation unit for generating manufacturing frame attribute data and manufacturing frame manufacturable item data, manufacturing frame attribute data unit for storing manufacturing frame attribute data, and manufacturing frame manufacturable item for storing manufacturing frame manufacturable item data A data base, a manufacturing base attribute data section that holds manufacturing base attribute data determined uniquely for the manufacturing base, and a product is manufactured at the manufacturing base. Product standard data section that holds data such as manufacturing man-hours, lots, manufacturing lead time, shipping lead time, manufacturing line name, direct material cost, and similar product standard data for multiple manufacturing bases, and product inventory The product inventory data section that holds the product inventory data shown, the order data section that holds the product order data, and the order allocation that performs the optimal allocation calculation by linear programming every time the order data is input from the order data section The product start data is generated in a certain cycle from the allocation result held by the calculation unit, the allocation result allocated by the order allocation calculation unit, and the allocation result allocated by the order allocation calculation unit. The production frame attribute data and the production frame manufacturable item data are deleted from the production frame attribute data part and the production frame manufacturable item data part, respectively. The product start data generation unit, the product start data unit that holds the product start data generated by the product start data generation unit, and the order data input to the order reservation calculation unit, the product inventory data, the product start data, the production frame An optimization parameter section that holds optimization parameters such as constraints and optimization priorities when assigning to attribute data and manufacturing frame manufacturable item data, and the order reservation calculation section receives order data from the order data section Each time is input, the manufacturing base attribute data held in the manufacturing base attribute data part 6, the product reference data held in the product reference data part, and the optimization parameter held in the optimization parameter part By referring to the parameters and the allocation results held in the allocation result holding unit, the optimization parameters are set for all the order data for which the allocation can be changed. Product inventory data held in the product inventory data part so as to optimize the optimization priority items held in the optimization parameter part within the range of the constraint conditions held in the data part, Provision for product start data held in the product start data section, manufacturing frame attribute data stored in the manufacturing frame attribute data section, and manufacturing frame manufacturable item data stored in the manufacturing frame manufacturable item data section RecalculateThis is a supply and demand adjustment system characterized by this.
[0028]
  The present invention provides the delivery date and the start instruction for the order by the above supply and demand adjustment method.And a step of manufacturing a product according to the delivery date and start instruction calculated by this step.This is a method for producing a product.
[0029]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
[0030]
FIG. 1 is a block diagram of the supply and demand adjustment system. The order data unit 1 holds order data including, for example, product items, requested delivery date, quantity, and the like. That is, for example, in assembly-type production activities, ordering of parts constituting a product is generally performed periodically. For example, MRP (Material Requirments Planning) is calculated once a week to calculate the excess / shortage of parts, order the shortage, and cancel the excess. However, the order data is composed of data such as such shortage orders and excess cancellations, and is updated each time these orders and cancellations are made. Therefore, the order data unit 1 is necessary for generating and updating manufacturing frame attribute data and manufacturing frame manufacturable item data stored in a manufacturing frame attribute data unit 4 and a manufacturing frame manufacturable item data unit 5 described later, respectively. Order data such as how many and how many parts are delivered is held.
[0031]
When the ordered parts are delivered, they are in stock. Also at this time, the order data is updated. At the same time, the parts inventory data is held in the parts inventory data section 2 as an increase in inventory.
[0032]
The parts inventory data section 2 includes parts necessary for generating and updating manufacturing frame attribute data and manufacturing frame manufacturable item data stored in the manufacturing frame attribute data section 4 and the manufacturing frame manufacturable item data section 5, respectively. Parts inventory data, such as how many are in stock, is retained.
[0033]
The production frame generation unit 3 periodically reads the order data stored in the order data unit 1 and the parts inventory data stored in the component inventory data unit 2, and based on the order data and the component inventory data, the manufacturing frame Attribute data and production frame manufacturable item data are generated. That is, the production frame generation unit 3 updates the production frame attribute data and the production frame manufacturable item data to the latest state at a timing designated based on the order data and the parts inventory data.
[0034]
The manufacturing frame attribute data and the manufacturing frame manufacturable item data are stored in the manufacturing frame attribute data unit 4 and the manufacturing frame manufacturable item data unit 5, respectively. The manufacturing frame attribute data part 4 and the manufacturing frame manufacturable item data part 5 may be deviated from what period at which manufacturing base, how many units and products can be manufactured, and how many days from the presented period. It is possible to hold each piece of data such that an excessive cost is required.
[0035]
Of these, the production frame attribute data includes, for example, a production frame ID, a production base (multiple possible) to be controlled by the supply and demand adjustment system, a quantity, an allocatable date, and the like. The production frame manufacturable item data includes, for example, a production frame ID, an item, an allocatable date, an advance date, an advance cost / piece, an advance cost / piece, and the like.
[0036]
For example, in a product composed of 10 parts, up to 9 points are common and one point is different. Assume that nine common parts have been ordered for 100 units, and one unique part has been ordered for 100 units each. In this case, each product can be produced by 100 units, but only 100 units can be produced in total. As a result, the production frame attribute data is one record, and the corresponding production frame manufacturable item data is two records.
[0037]
Also, the allocation date is the time when the time required for manufacturing is added from the required delivery date of the parts.
In some cases, it may be possible to manufacture the product earlier than the assignable date. However, there is a possibility that the cost may be further increased because parts must be delivered in advance. This cost is stored in the advance cost of the production frame manufacturable item data, and the time when advance is possible is stored on the advance possible date.
[0038]
Conversely, there is a limit that allows parts to be interpolated without incurring extra costs. This day is an assignable date, and if this allocatable date is passed, there is a possibility that the cost of storing parts may be increased. This cost is postponed and stored in the cost.
[0039]
The manufacturing base attribute data section 6 holds, for example, manufacturing base attribute data determined uniquely for the manufacturing base, such as manufacturing line data of a manufacturing base to be controlled by the supply and demand adjustment system, a load upper limit man-hour of the manufacturing line, and labor costs. To do.
[0040]
The product standard data section 7 includes, for example, data such as manufacturing man-hour, lot number, manufacturing lead time, shipping lead time, manufacturing line name, and direct material cost when one product is manufactured at a manufacturing base. And the same product standard data for a plurality of manufacturing bases is held.
[0041]
The product inventory data section 8 holds product inventory data such as which products are present and how many are in stock.
[0042]
The product start data unit 9 holds product start data such as which and how many products generated by the product start data generation unit 10 described later are produced.
[0043]
The product start data generation unit 10 generates product start data in a certain cycle from the allocation result assigned by the order reservation calculation unit 13 to be described later, and the manufacturing frame attribute data and the manufacturing frame manufacturable items that become the product start data The data is deleted from the production frame attribute data part 4 and the production frame manufacturable item data part 5, respectively.
[0044]
The order data section 11 stores order data such as what products, when, where and how many from customers. This order data comes in at any time.
[0045]
The optimization parameter unit 12 assigns the order data input to the order allocation calculation unit 13 to the product inventory data, product start data, production frame attribute data, and production frame manufacturable item data by the order allocation calculation unit 13. Holds parameters such as constraints and optimization priorities that must be considered.
[0046]
Of these, for example, the restriction condition must not assign the same order across a plurality of manufacturing bases. In other words, the constraint condition is, for example, a content that an order once assigned should not be reassigned so that a delivery date after the delivery date answered. Such contents vary depending on the business and are given by parameters.
[0047]
The demand prediction data unit 14 holds demand prediction data in which a customer predicts which product, when, where, and how many units. This demand prediction data enhances the optimization effect when the order reception data calculation unit 13 optimizes the reservation.
[0048]
The allocation result holding unit 15 holds the allocation result allocated by the order allocation calculation unit 13.
[0049]
The order allocation calculation unit 13 performs an optimal allocation calculation by a linear programming method, and each time the order data is input from the order data unit 11, the manufacturing site attribute data held in the manufacturing site attribute data unit 6, The provision can be changed by referring to the product reference data held in the product reference data section 7, the parameters held in the optimization parameter section 12, and the allocation result held in the allocation result holding section 15. In order to optimize the optimization priority items held in the optimization parameter section 12 within the range of the constraint conditions held in the optimization parameter section 12 for all received order data Product inventory data held in the inventory data portion 8, product start data held in the product start data portion 9, and manufacturing frame attribute data stored in the manufacturing frame attribute data portion 4 Recalculate the reserve to the manufacturing frame manufacturability material data stored in the production frame manufacturability item data section 5.
[0050]
Next, the operation of the supply and demand adjustment system configured as described above will be described.
[0051]
The production frame generation unit 3 periodically reads the order data stored in the order data unit 1 and the parts inventory data stored in the component inventory data unit 2, and based on the order data and the component inventory data, the manufacturing frame Attribute data and production frame manufacturable item data are generated. The manufacturing frame attribute data and the manufacturing frame manufacturable item data are stored in the manufacturing frame attribute data unit 4 and the manufacturing frame manufacturable item data unit 5, respectively.
[0052]
The order allocation calculating unit 13 receives the manufacturing site attribute data held in the manufacturing site attribute data unit 6 and the product standard held in the product standard data unit 7 every time the order data is input from the order data unit 11. Optimization parameters for all order data that can be changed in allocation by referring to the data, parameters held in the optimization parameter unit 12 and allocation results held in the allocation result holding unit 15 Product inventory data held in the product inventory data unit 8 so as to optimize the optimization priority items held in the optimization parameter unit 12 within the range of the constraint conditions held in the unit 12 Product start data held in the product start data section 9, manufacturing frame attribute data stored in the manufacturing frame attribute data section 4 and the manufacturing frame manufacturable item data section 5, and To re-calculate the reserve to the concrete frame can be manufactured item data.
[0053]
That is, as shown in FIG. 2, the order allocation calculation unit 13 receives the manufacturing site attribute data, the product reference data, the parameter, the allocation result, and the like every time the order data including, for example, a product item, requested delivery date, and quantity is input. In order to answer the delivery date of the order data so that the optimization priority item is optimized within the range of the parameter constraint conditions, the inventory currently held is shipped, or the manufacturing instruction and the manufacturable frame are The allocation process of whether to manufacture and ship in time for delivery is performed, and the allocation result and its scheduled shipping date are output.
[0054]
Further, the order reservation calculation unit 13 takes in the demand prediction data in which the customer from the demand prediction data unit 14 predicts which product, what time, where, and how many units, and performs the allocation process to enhance the optimization effect. The allocation result and the estimated shipping date are output.
[0055]
Specifically, the order reservation calculation unit 13 periodically starts processing every 15 minutes, for example. The basic rules for allocation are in time for delivery of orders and closest to the delivery date.
[0056]
For example, if the delivery date of an order is two days later, and there is no product start data and manufacturable frame that will be completed in two days, and there is an inventory that is not determined by the customer, the order allocation calculator 13 assigns the inventory to the inventory. .
[0057]
Further, for example, if there is product start data that will be completed in 4 days after the delivery date of an order, and there is a manufacturable frame that will be completed in 6 days, and there is an unspecified customer inventory, If it is assigned to a completed manufacturable frame after a day, the delivery date will be delayed.
Therefore, in this case, the order reservation calculation unit 13 assigns the product start data to be completed after 4 days. The delivery date can be met even if orders are allocated to stock.
[0058]
The determination of which to allocate is made based on the amount of storage that the inventory has already taken, or whether there is a possibility of receiving an order requiring immediate delivery within 4 days, for example.
[0059]
For example, there are two orders with different delivery dates after 10 days, for example. Although there is a manufacturable frame that can meet the delivery date for these orders, there is a case where the production line capacity exceeds the capacity of the production line when it is manufactured at the same manufacturing base on the same day.
[0060]
In such a case, it is conceivable to allocate the quantity that exceeds the capacity of either order ahead of schedule. Here, the order allocation calculation unit 13 determines that the inventory storage cost for the excess cost and the amount of inventory storage due to advance is small.
[0061]
In this way, the order reservation calculation unit 13 calculates where the order data from the order data unit 11 is allocated. At this time, the order allocation calculation unit 13 assigns a certain index to an optimum value as a whole within a re-assignable range even for the part assigned in the past.
[0062]
This index is, for example, a delivery date compliance rate, inventory holding days, production load fluctuation rate, and excessive cost. Of these, the maximum delivery rate compliance is optimal, the minimum number of days in inventory is optimal, the minimum production load fluctuation rate is optimal, and the minimum excess cost is optimal.
[0063]
The order in which these indexes are preferentially optimized is given by parameters such as the constraint conditions and optimization priority stored in the optimization parameter unit 12.
[0064]
The order reservation calculation unit 13 replies the delivery result to the order with the assigned result.
The basic rule for answering the delivery date is that the requested delivery date is returned if the allocation is made before the requested delivery date. In addition, when the allocation is made after the requested delivery date, the delivery date is calculated in consideration of the period from the allocation date until the product can be shipped, and the delivery date is answered. In this case, delivery is delayed.
[0065]
The allocation result calculated by the order allocation calculation unit 13 is stored in the allocation result holding unit 15.
[0066]
The product start data generation unit 10 is activated at a preset fixed cycle, extracts a manufacturable frame to be generated as product start data from the allocation result assigned by the order reservation calculation unit 13, and converts it into product start data. . For example, on every Tuesday, the manufacturable frame allocated in the following week is converted into product start data. Further, for example, the manufacturable frame allocated every day after three days is converted into product start data.
[0067]
At the same time, the product start data generation unit 10 deletes the manufacturing frame attribute data and the manufacturing frame manufacturable item data that are the product start data from the manufacturing frame attribute data unit 4 and the manufacturing frame manufacturable item data unit 5, respectively.
[0068]
Then, the product is manufactured in accordance with the delivery date of the allocation result calculated by the order allocation calculation unit 13 and the start instruction.
[0069]
In the case of the supply and demand adjustment system as described above, the manufacturable frame is defined to have variability as much as possible. Therefore, under the constraints given by the variable range of the manufacturable frame and the optimization parameters. By allocating the manufacturable frame so that the target function is maximized, it is possible to plan and implement a construction plan with less management loss.
[0070]
In other words, while taking advantage of the seat reservation system that makes it possible to make an immediate delivery date response for production and the ease of creating a construction instruction, it is possible to derive an allocation result that is reasonable for the delivery date compliance rate, the number of days of inventory holding, and the production load fluctuation range, Management loss that could not be prevented in the past can be reduced, and human work that has occurred to prevent management loss can be reduced.
[0071]
In addition, the customer from the demand forecast data section 14 takes in demand forecast data that predicts which products, when, where, and how many, and performs the provisioning process, and the provision result and the scheduled shipping date that enhances the optimization effect Therefore, when orders are received according to a certain amount of demand forecast, it is possible to perform allocation in advance so as not to cause almost any management loss, and further effects can be expected. That is, when the accuracy of demand prediction is high, management loss can be further suppressed.
[0072]
Furthermore, the effect of the said supply and demand adjustment system is demonstrated.
[0073]
First, it is possible to reallocate orders.
[0074]
In other words, the order allocation calculation unit 13 calculates the allocation of all orders including orders for which the delivery date has already been answered when a new order is received and the order allocation and delivery date response processing is performed. However, for orders that have already been replied, allowances are calculated within the scope of keeping the replied delivery date. This re-allocation calculation for orders that have already been answered ensures production capacity (production instructions and manufacturable frames) that is earlier than the delivery date, and orders with short delivery dates that arrive later are on time. It is possible to prevent production from becoming impossible.
[0075]
In addition, when so-called collective provisioning is used to collect orders for a certain period of time, provisions can be made in ascending order until the delivery date. Can be suppressed. When it becomes possible to re-allocate orders, the allocation date of the orders that have already been queried can be changed for short-term orders that came later, even in the provisioning system. The result is that the delay in delivery is the same as when it was done.
[0076]
Next, production candidate items can be set in the manufacturable frame.
[0077]
That is, when a plurality of items can be manufactured with one manufacturable frame depending on the procurement status of the members, a plurality of manufacturing candidate items are set. This member procurement situation assumes a case as shown in FIG. 3, for example.
[0078]
Member P₁And P₂Product A produced in combination with the component P₂And P₃And product B produced in combination. Part P₂Is a member common to the products A and B. Each member P₁, P₂, P₃Each takes an order lead time of 10 days, 15 days, and 8 days, for example.
[0079]
For example, if a W + 4 week manufacturable frame member has to be delivered by W + 2 week, member P₂Must be ordered on the first day of week W and member P₁By the first day of week W + 1, member P₃Must place an order by the third day of week W + 1.
[0080]
In the period “1” until the week W, the member P which is a common member of the products A and B₂However, since the products A and B can be manufactured in the week W + 4, orders for the products A or B can be allocated up to, for example, 100 units in the week W + 4.
[0081]
However, in the period “2” after W + 1 week, the member P of the product A₁Because the ordering timing of₁The amount of product A that can be manufactured is determined in accordance with the order quantity.
[0082]
A member P capable of manufacturing 100 products A.₁, The product A can only be manufactured in the week W + 4, and the order for the product B cannot be allocated in the week W + 4. In this case, in the period “2”, only the product A is the production candidate item of the w + 4 week production available frame.
[0083]
When manufacturing candidate items are determined in this way, the contents of ordering of parts change depending on the allocation result, and the result of the delivery date reply is transmitted to, for example, the parts procurement department in the company.
For example, in the delivery date reply for the period “1” shown in FIG. 3, for example, when 30 units of orders for product A are allocated in the W + 4 week manufacturable frame, 30 products A are stored on the first day of W + 1 week Manufactured bamboo P₁Order.
[0084]
Next, the manufacturable frame can be moved forward and backward.
[0085]
In other words, it is possible to move ahead of the day or week on which the manufacturable frame is set according to the order status, and take it forward (advance), and postpone it later (allow it later). The results of the advancement of the manufacturable frame and the postponement of the manufacturable frame are transmitted to, for example, a member procurement department in the company, and the delivery schedule of the member is changed as necessary.
[0086]
FIG. 4 is a diagram showing an example of forward and backward. Here, the manufacturable frame is W + 4 weeks and the production candidate items A, B, and C are set to a quantity of 100 units. In this example, it is assumed that the manufacturable frame can be advanced two weeks ahead, and one week later.
[0087]
First of all, an order to be manufactured in week W + 4 can be allocated unconditionally.
[0088]
Next, if it is desired to manufacture an order for product A in W + 2 weeks, but there is no other manufacturing resource to allocate, a part of the W + 4 week manufacturable frame can be moved to W + 2 week and allocated. In this case, an advance excess cost in proportion to the quantity advanced in W + 2 weeks is required.
[0089]
In addition, in the case of lot manufacturing in which a plurality of units are manufactured at the same time instead of one unit, a part of the advanced quantity may not be reserved for orders and may remain. In such a case, after W + 2 weeks, it can be shipped at any time for other orders, but it costs product inventory storage from the date of manufacture to the date of shipment.
[0090]
The same applies to postponement. Part of the W + 4 week manufacturable allowance can be reserved for orders for manufacturing products B and C in W + 5 weeks. In this case as well, there is an excess cost that is proportional to the quantity that was postponed, and a product inventory storage cost for the surplus product in the postponed quantity.
[0091]
Next, optimal allocation calculation is possible by linear programming.
[0092]
Linear programming defines the quantity to be determined as a decision variable and, under the constraints of the linear equality or linear inequality written using this decision variable, also maximizes the objective function of the linear expression related to the decision variable. This is a method of calculating the optimum value of the decision variable to be minimized.
[0093]
There is also a dramatic improvement in computational capabilities in recent years. By using a general-purpose optimization engine, the optimal value of a decision variable that satisfies tens of thousands and millions of constraint conditions can be calculated in a few minutes. Is guaranteed to be theoretically optimal. In order to use linear programming, there are the following two restrictions.
[0094]
(a) The value of the decision variable is a real number and cannot be limited to an integer value.
[0095]
(b) The constraint condition and the objective function must be described by a primary expression (linear) of the decision variable.
[0096]
However, even if the optimal value of the decision variable obtained by linear programming is rounded and converted to an integer, the objective function does not deteriorate so much, and it can be described by a linear expression with almost all constraints. Not a thing. Thus, linear programming is used for various decision support models.
[0097]
In the above supply and demand adjustment system, the amount of provisions to the manufacturable frame of orders is used as a decision variable, the constraint conditions necessary for the provision calculation are described by a linear expression, the number of days for delivery deadlines and the number of days for product inventory storage are used as objective functions, and linear Use planning methods to obtain optimal allocation results. Since a plurality of evaluation measures can be added to the objective function as weighted counts at the same time, an optimum allocation result considering a plurality of evaluation measures can be obtained. An example of the constraint condition expression is shown in Expression (1), and an example of the objective function is shown in Expression (2).
[0098]
[Expression 1]

[0099]
The constraint condition expression of Formula (1) expresses the constraint condition that “the total of the reserved order quantity is equal to the requested order quantity” as a primary expression of the decision variable. C is a decision variable indicating when and how many orders are allocated at which manufacturing site. q is a request variable (input data) for each order. The left side of the linear expression is a value obtained by summing the decision variable C for all manufacturing bases f and all times (τ, t), and represents the total value of the quantities allocated within the planning period. The constraint condition means that the value on the left side is equal to the required quantity q of the order k on the right side. In this way, all constraints necessary for order reservation calculation are described by a linear expression.
[0100]
In the objective function of Expression (2), a plurality of evaluation measures are combined with three weighting factors α, β, and γ. In this formula, DV is the number of days for delivery deadline, PHC is the number of days of inventory holding, EDC is the advance / postponement cost, PC is the manufacturing cost, MC is the material purchase cost, and PM is the production leveling scale.
[0101]
The values of the weighting factors α, β, γ need to be given before the execution of linear programming. When the value of the weighting coefficient α is set to be large, an allocation result is obtained so that the number of days of delivery violation is as small as possible, and when the value is set to be small, an allocation result is obtained so that the number of inventory storage days and each expense is as small as possible.
[0102]
Note that the present invention is not limited to the above-described embodiment, and can be variously modified without departing from the scope of the invention in the implementation stage.
[0103]
Furthermore, the above embodiments include inventions at various stages, and various inventions can be extracted by appropriately combining a plurality of disclosed constituent requirements. For example, even if some constituent elements are deleted from all the constituent elements shown in the embodiment, the problem described in the column of the problem to be solved by the invention can be solved, and is described in the column of the effect of the invention. If the effect is obtained, a configuration from which this configuration requirement is deleted can be extracted as an invention.
[0104]
【The invention's effect】
As described in detail above, according to the present invention, it is easy to create an immediate delivery date reply and start instruction for production, and derive an allocation result that is reasonable for the delivery date compliance rate, the number of days of inventory holding, and the production load fluctuation range. Supply and demand adjustment method and system and product manufacturing method can be provided.
[Brief description of the drawings]
FIG. 1 is a block diagram showing an embodiment of a supply and demand adjustment system according to the present invention.
FIG. 2 is a schematic diagram showing an allocation process in an embodiment of a supply and demand adjustment system according to the present invention.
FIG. 3 is a schematic diagram showing an example of a material procurement status in the allocation process in the embodiment of the supply and demand adjustment system according to the present invention.
FIG. 4 is a diagram showing an example of forward and backward in an embodiment of a supply and demand adjustment system according to the present invention.
FIG. 5 is a schematic diagram for explaining a conventional method for creating an order reservation / starting instruction.
[Explanation of symbols]
1: Order data section, 2: Parts inventory data section, 3: Manufacturing frame generation section, 4: Manufacturing frame attribute data section, 5: Manufacturing frame manufacturable item data section, 6: Manufacturing base attribute data section, 7: Product standard Data section, 8: Product inventory data section, 9: Product start data section, 10: Product start data generation section, 11: Order reception data section, 12: Optimization parameter section, 13: Order reservation calculation section, 14: Demand forecast data Part, 15: allocation result holding part.

Claims (9)

In the supply and demand adjustment method of receiving an order for a product, performing an allocation calculation according to at least a production plan and a procurement status of parts constituting the product, and outputting a delivery date and a start instruction for an order for the product,
Periodically, at least the product is a manufacturing base based on order data consisting of at least the product item, required delivery date and quantity, and parts inventory data indicating how many parts of the product are in stock, and a predetermined period A first step of generating manufacturing frame attribute data and manufacturing frame manufacturable item data indicating how many units can be manufactured,
A second step of holding product inventory data indicating the inventory of the product;
A third step of holding manufacturing base attribute data uniquely determined for the manufacturing base;
When manufacturing the product at the manufacturing base, data such as manufacturing man-hours, lots, manufacturing lead time, shipping lead time, manufacturing line name, direct material cost, and similar product standard data for a plurality of manufacturing bases are retained. A fourth step;
A fifth step of holding order data of the product;
A sixth step of performing an optimal allocation calculation by linear programming each time the order data is input;
A seventh step of holding the allocation result allocated in the sixth step;
Product start data is generated in a certain cycle from the allocation result allocated in the sixth step, and the manufacturing frame attribute data and the manufacturing frame manufacturable item data that are the product start data are deleted, respectively. Process,
A ninth step of holding the product start data generated by the eighth step;
When the order data input to the fourth step is allocated to the product inventory data, the product start data, the production frame attribute data, and the production frame manufacturable item data, the optimum conditions such as the constraint condition and the optimization priority A tenth step of retaining the parameters of the conversion;
Have
The sixth step refers to the manufacturing site attribute data, the product standard data, the optimization parameter, and the allocation result each time the order data is input, and the allocation change is performed. For all possible order data, the product inventory data, the product start data, and the manufacturing frame attribute data, so as to optimize the optimization priority items within the range of the constraints Recalculate the allowance for the production allowance item data;
Supply and demand adjustment method characterized by this.   2. The supply and demand adjustment method according to claim 1, further comprising a step of holding demand prediction data predicting the order and supplying the demand prediction data to the allocation calculation.   The data relating to the product manufacturing base includes at least data determined uniquely for the manufacturing base, such as manufacturing line data of the manufacturing base, load upper limit man-hours of the manufacturing line, and labor costs. The supply and demand adjustment method described.   The reference data relating to the product manufacturing includes at least manufacturing man-hours, lot numbers, manufacturing lead times, shipping lead times, manufacturing line names, direct material costs, and similar product reference data for a plurality of manufacturing bases. The supply and demand adjustment method according to claim 1 or 2.   The optimization parameter includes the constraint condition for reallocation so that the delivery date after the delivery date for which the order once assigned is replied, and the optimization priority when the allocation is made. The supply and demand adjustment method according to 1 or 2. In the supply and demand adjustment system that receives an order for a product, performs an allocation calculation according to at least the production plan and the procurement status of parts constituting the product, and outputs a delivery date and a start instruction for an order for the product.
An order data part 1 for holding order data consisting of at least the product item, requested delivery date, and quantity;
A parts inventory data section 2 for holding parts inventory data indicating how many parts of the product are in stock;
The order data stored in the order data part 1 and the part inventory data stored in the part inventory data part 2 are periodically read out, and at least the product is manufactured at the manufacturing base based on the order data and parts inventory data. A manufacturing frame generation unit 3 for generating manufacturing frame attribute data and manufacturing frame manufacturable item data indicating how many units can be manufactured in a predetermined period;
A manufacturing frame attribute data section 4 for storing the manufacturing frame attribute data;
Manufacturing frame manufacturable item data section 5 for storing the manufacturing frame manufacturable item data;
A manufacturing base attribute data section 6 for holding manufacturing base attribute data uniquely determined for the manufacturing base;
When manufacturing the product at the manufacturing base, data such as manufacturing man-hours, lots, manufacturing lead time, shipping lead time, manufacturing line name, direct material cost, and similar product standard data for a plurality of manufacturing bases are retained. Product standard data section 7;
A product inventory data section 8 for storing product inventory data indicating the inventory of the product;
An order data section 11 for storing the order data of the product;
An order provision calculation unit 13 that performs an optimal allocation calculation by linear programming every time the order data is input from the order data unit 11;
An allocation result holding unit 15 for holding the allocation result allocated by the order allocation calculation unit 13;
The order provision produces the product starts data at a constant cycle from the reserve result of the allocation by the calculation unit 13, the product starts the manufacturing frame attribute data and the manufacturing frame manufacturability material data the manufacturing frame attribute data becomes data Product start data generation unit 10 to be deleted from each of the unit 4 and the production frame manufacturable item data unit 5;
How many of the products generated by the product starts data generating unit 10, a product construction data unit 9 for holding the product starts data indicating the manufacturing facilities are producing,
When the order data input to the order allocation calculation unit 13 is allocated to the product inventory data, the product start data, the manufacturing frame attribute data, and the manufacturing frame manufacturable item data, restrictions and optimization priorities An optimization parameter unit 12 for holding optimization parameters;
Comprising
The order allocation calculation unit 13 stores the manufacturing site attribute data held in the manufacturing site attribute data unit 6 and the product reference data unit 7 every time the order data is input from the order data unit 11. Change the allocation by referring to the product standard data held, the optimization parameter held in the optimization parameter unit 12, and the allocation result held in the allocation result holding unit 15 Optimize optimization priority items held in the optimization parameter unit 12 within the range of the constraint conditions held in the optimization parameter unit 12 for all the order data that can be processed As described above, the product inventory data held in the product inventory data portion 8, the product start data held in the product start data portion 9, and the manufacturing frame attribute The manufacturing frame attribute data stored in over data unit 4 recalculates the reserve to the Production frame manufacturability material data stored in the production frame manufacturability item data section 5,
Supply and demand adjustment system characterized by this.   7. The supply and demand adjustment system according to claim 6, further comprising demand forecast data means for holding demand forecast data for forecasting the order and supplying the demand forecast data to the allocation calculation. The order allocation calculation unit 13 uses the allocation quantity of the order received in the manufacturable frame as a decision variable, describes the constraint condition necessary for the allocation calculation by a linear expression, and indicates the number of delivery date violation days, product inventory storage days, etc. The objective function is used to obtain an optimal allocation result by using the linear programming method. The following equation (1) shows the constraint condition equation, and the following equation (2) shows the objective function.

C is a variable for determining when and how many times the order is allocated at the manufacturing base, q is a required quantity that is a request variable for each order, f is a manufacturing base, (τ, t) is all times, k is an order, α, β, γ are weighting factors, DV is the number of days for delivery deadline, PHC is the number of days in stock, EDC is the advance / postponement cost, PC is the manufacturing cost, MC is the material purchase cost, PM is the production leveling scale,
The supply and demand adjustment system according to claim 6. Calculating the delivery date and the start instruction for the order by the supply and demand adjustment method according to any one of claims 1 to 5;
A step of manufacturing the product according to the delivery date and the start instruction calculated by this step;
A method for producing a product, comprising:

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