JP4679091B2 - Production management system for resetting production plan and program for executing the system - Google Patents

Description

  The present invention includes (1) customer demand, (2) production capacity, (3) a production management system that resets a production plan in accordance with various changes that occur in production activities, such as material procurement conditions, and the like The present invention relates to a program for causing a production management system to perform resetting.

  Conventionally, various production management systems have been developed and operated for the purpose of improving the production efficiency of factories. By using such a production management system, the user can input the required amount of parts, equipment machinery, personnel, etc. that make up the product to be produced by inputting the predicted customer demand, production capacity, material procurement conditions, etc. Calculation (MRP; Material Resource Planning) can be used to set and operate a production plan.

  Production management systems have worked effectively to set up and reliably execute production plans in response to anticipated demand. More specifically, by grasping the actual production status on the computer based on a predetermined production plan, the necessary parts procurement, production process start and end instructions, etc. are properly performed, As a result, we were able to maximize the productivity by effectively using the materials.

Japanese Patent Application No. 2000-79023

  However, in the present day, a situation has arisen that cannot be handled by such a conventional production management system. For example, there is a diversification of customer preferences and an increase in the rate of preference changes. As a result, product order conditions change frequently, and production sites often have to change their initially set production plans. In such a situation, the following problems exist.

  For example, if customer demand changes and there is a sudden order inquiry, the availability of tens of thousands of parts, sometimes from thousands of parts vendors, It is necessary to immediately grasp the procurement conditions and production capacity of materials such as ordering status, change the initial production plan to determine whether it can be produced on the desired delivery date, and if possible, actually change the production plan is there. Such a plan change request is not only due to a change in customer demand as in this example, but also a change in production capacity due to equipment failure, worker illness or injury, or a scheduled delivery date or quantity of a component vendor. It also occurs due to changes in the procurement conditions for materials such as a change request.

  The conventional production management system has been rigid with respect to such various changes. For example, when customer demand changes, the conventional production management system uses parts, intermediate products, products, etc., surplus ranges of production capacity such as equipment, personnel, etc., parts of parts vendors set in advance The possibility of changing the production plan is determined while fixing the procurement conditions of materials such as delivery conditions. Therefore, for example, even if it is possible to negotiate with the parts vendor at the production site and deliver it ahead of the normal delivery date, or change the number of delivered lots, the conventional production management system The plan that has already been ordered (confirmed) cannot be changed. As a result, a gap occurs between the plan and the actual production, and the actual production situation can no longer be simulated on the system. In other words, since there is no system for accurately simulating the special response on the part vendor side, it is not possible to accurately determine whether or not the response is possible, and the opportunity to receive an order is completely missed. Here is the first problem of the conventional production management system.

  By the way, even when the production capacity changes or the procurement conditions of materials change, the conventional production management system cannot accept such a change. Therefore, when such a change is actually realized, a divergence occurs between the actual production plan and the production plan on the production management system. This is the second problem of the conventional production management system.

  The present invention has been made in view of such problems, and an object of the present invention is to provide a system that can flexibly cope with changes in various surrounding circumstances.

  In order to achieve such an object, the present invention provides the following.

(1) A server that is connected to a terminal via a communication network, calculates an order condition that can be accepted in accordance with a change in the order condition sent from the terminal, and transmits the received order condition to the terminal.
A storage unit including at least a product order condition storage area for storing product order conditions and a parts procurement condition storage area for storing part procurement conditions;
Product order condition receiving means for receiving product order conditions from the terminal;
Parts procurement condition transmitting means for transmitting the parts procurement conditions calculated based on the product order conditions to the terminal;
Parts procurement condition receiving means for receiving updates to the parts procurement conditions from the terminal;
A server comprising: product order condition transmission means for transmitting a product order condition calculated based on the received parts procurement conditions to the terminal.

  According to the invention of (1), an acceptable product order condition can be calculated by updating a part procurement condition calculated in accordance with a change in a product order condition occurring in a production activity on the part vendor side. . In particular, with regard to parts procurement conditions, tens of thousands of parts procurement conditions updated by thousands of parts vendors, each of which can be accepted, are automatically aggregated and reflected in the calculation of acceptable product order conditions. be able to. As a result, it is possible to cope with changes in product order conditions that cannot be accepted unless the parts procurement conditions are updated.

  As described above, in modern production activities, such changes in product order conditions frequently occur, and the fact that the “partial order” according to the present invention is possible greatly changes the order rate. In other words, by introducing a new stage of updating the parts procurement conditions once calculated based on conditions such as procurement lead time and the number of procurement lots, the product order opportunity given in consideration of the special response of the parts vendor side Can be acquired without missing as much as possible. In addition, since the production plan itself has been updated after such a response, if new product order conditions change, the new ordering opportunities will continue to be acquired repeatedly with the same calculation accuracy as the previous time. Can do.

(2) A server that is connected to a terminal via a communication network, calculates an influence on a product delivery condition according to a change in component procurement conditions sent from the terminal, and transmits the result to the terminal,
The server includes a storage unit including at least a parts procurement condition storage area for storing parts procurement conditions, a production plan storage area for storing production plans, and a product delivery condition storage area for storing product delivery conditions, ,
Parts procurement condition receiving means for receiving parts procurement conditions from the terminal;
Production plan transmission means for transmitting the production plan calculated based on the parts procurement conditions to the terminal;
Production plan receiving means for receiving updates to the production plan from the terminal;
A server comprising: product delivery condition transmission means for transmitting product delivery conditions calculated based on the received production plan to the terminal.

  According to the invention of (2), contrary to the invention of (1), the product manufacturer can update the production plan calculated according to the change in the parts procurement conditions on the part vendor side, thereby satisfying the product delivery conditions. The impact can be calculated. In particular, regarding parts procurement conditions, tens of thousands of parts procurement conditions changed by thousands of parts vendors can be automatically aggregated and reflected in the production plan calculation.

  As described above, in modern production activities, such changes in parts procurement conditions may occur at the same time, and the rapid calculation of the impact on product delivery conditions according to the present invention maintains the existing product order conditions. Will play an important role. In other words, by introducing a new stage of updating the production plan once calculated based on conditions such as production lead time and workload, existing product order conditions can be considered as much as possible taking into account the special response of the product manufacturer. It can be maintained. Furthermore, since the production plan itself has been updated even after such a response, it is possible to continue to respond repeatedly with the same calculation accuracy as the previous time when a new change in parts procurement conditions occurs.

(3) In the server described in (1),
The storage unit further includes a product inventory information storage area for storing product inventory information, a parts inventory information storage area for storing parts inventory information, a parts procurement lead time storage area for storing part procurement lead times, and a production plan A production plan storage area for storing
A server comprising: a production plan determining means for determining the production plan including a buffer in the product inventory information, the component inventory information, and the component procurement lead time.

(4) In the server described in (2),
The storage unit further includes a product inventory information storage area for storing product inventory information, a parts inventory information storage area for storing parts inventory information, and a parts procurement lead time storage area for storing component procurement lead times. In addition,
A server comprising: a production plan determining means for determining the production plan including a buffer in the product inventory information, the component inventory information, and the component procurement lead time.

  According to the invention of (3) or (4), the production plan is determined including the buffer in the product inventory, the parts inventory, and the parts procurement lead time. On the other hand, these changes can be accommodated without changing the production plan within the range of these buffers.

(5) A production management program for calculating an order receiving condition that can be accepted according to a change in the order receiving condition sent from the terminal to a server connected to the terminal via a communication network, and transmitting the order receiving condition to the terminal. There,
The server includes a control unit and a storage unit,
Here, the storage unit includes at least a product order condition storage area for storing product order conditions, and a parts procurement condition storage area for storing part procurement conditions,
For the control unit
Product order condition reception processing for receiving product order conditions from the terminal;
Parts procurement condition transmission processing for sending the parts procurement conditions calculated based on the product order conditions to the terminal;
Parts procurement condition reception processing for receiving updates to the parts procurement conditions from the terminal;
A product management program for executing a product order condition transmission process for transmitting a product order condition calculated based on the received parts procurement conditions to the terminal.

(6) Production management for causing a server connected to a terminal via a communication network to calculate an effect on product delivery conditions according to a change in component procurement conditions sent from the terminal and transmit the result to the terminal A program,
The server includes a control unit and a storage unit,
Here, the storage unit includes at least a parts procurement condition storage area for storing part procurement conditions, a production plan storage area for storing production plans, and a product delivery condition storage area for storing product delivery conditions, ,
For the control unit
Parts procurement condition reception processing for receiving parts procurement conditions from the terminal;
A production plan transmission process for transmitting the production plan calculated based on the parts procurement conditions to the terminal;
Production plan reception processing for receiving an update to the production plan from the terminal;
A production management program for executing a product delivery condition transmission process for transmitting a product delivery condition calculated based on the received production plan to the terminal.

(7) In the production management program described in (5),
The storage unit further includes a product inventory information storage area for storing product inventory information, a parts inventory information storage area for storing parts inventory information, a parts procurement lead time storage area for storing part procurement lead times, and a production plan A production plan storage area for storing
For the control unit
A production management program for executing a production plan determination process for determining the production plan including a buffer in the product inventory information, the component inventory information, and the component procurement lead time.

(8) In the production management program described in (6),
The storage unit further includes a product inventory information storage area for storing product inventory information, a parts inventory information storage area for storing parts inventory information, and a parts procurement lead time storage area for storing component procurement lead times. In addition,
For the control unit
A production management program for executing a production plan determination process for determining the production plan including a buffer in the product inventory information, the component inventory information, and the component procurement lead time.

According to the present invention described above, the following effects can be expected.
(A) Contributes to improving and speeding up production management and saving labor in production management costs.
(B) Based on (a), it contributes to the improvement of the ability to respond to the changes that occur on the production site.

  Hereinafter, the best mode for carrying out the present invention will be described with reference to the drawings. This is merely an example, and the technical scope of the present invention is not limited to this.

  FIG. 1 is a block diagram showing the overall configuration of a system according to the present invention. The server 4 is connected to a personal computer 3 as a terminal via the communication network 2. The communication network 2 is, for example, a LAN or the Internet network, but is not limited to this as long as it is a communication network capable of transmitting and receiving information.

  The server 4 transmits and receives information via the personal computer 3 and the communication network 3.

  FIG. 2 is a block diagram showing a configuration of the personal computer 3 as a terminal. A control unit 31, a storage unit 32, a communication interface unit 33, a display unit 34 and an input unit 35 are connected via a bus 36, and the control unit 31 controls the entire personal computer 3.

  The control unit 31 receives user input at the input unit 35 and transmits / receives information to / from the server 4 via the communication interface unit 33.

  FIG. 3 is a block diagram showing the configuration of the server 4. A control unit 41, a storage unit 42, a communication interface unit 43, a display unit 44, and an input unit 45 are connected via a bus 46, and the control unit 41 controls the entire server 4. The storage unit 42 is a product order condition storage area for storing product order conditions, a part procurement condition storage area for storing part procurement conditions, a product delivery condition storage area for storing product delivery conditions, and a part for storing part information. An information storage area, a manufacturing process information storage area for storing manufacturing process information, a product inventory information storage area for storing product inventory information, a parts inventory information storage area for storing parts inventory information, and parts ordering information are stored. Stores part order information storage area, manufacturing process load information storage area for storing manufacturing process load information as part of production plan, parts procurement lead time storage area for storing part procurement lead time, and number of parts procurement lots And a parts procurement lot number storage area.

  The control unit 41 transmits / receives information to / from the personal computer 3 via the communication interface unit 43.

  The storage unit 42 stores a production management program, and the server 4 reads out and executes this program to perform various processes in cooperation with the above hardware. Further, by this, the server 4 and the personal computer 3 as a terminal function as a production management system.

  FIG. 4 is a block diagram showing an example of the configuration of screen display information displayed on the display unit 34 by the control unit 31 of the personal computer 3 on the product manufacturer side.

  The control unit 31 causes the display unit 34 to display, as new product order information, an input column for product order conditions including a product code, delivery date, and quantity. The person in charge of the product manufacturer can input the order receiving condition of the product when there is a new product ordering opportunity from the customer.

  FIG. 5 is a block diagram showing another example of the configuration of screen display information displayed on the display unit 34 by the control unit 31 of the personal computer 3 on the part vendor side.

  The control unit 31 causes the display unit 34 to display a component procurement condition including a component code, a delivery date, and a quantity as new component order information. These parts procurement conditions can be updated to parts procurement conditions acceptable on the part vendor side.

  FIG. 6 is a block diagram showing another example of the configuration of screen display information displayed on the display unit 34 by the control unit 31 of the personal computer 3 on the product manufacturer side.

  The control unit 31 causes the display unit 34 to display a product order condition including a product code, a delivery date, and a quantity as acceptable new product order information. The person in charge of the product manufacturer can tell the customer about the acceptable order conditions by looking at this screen.

  FIG. 7 is a diagram showing an example of component information according to the present invention. In this example, in order to configure the product A, it is indicated that a part a is 1, a part b is 25, and the like. Further, it is shown that the component α is 5, the component β is 8, and the like to configure the component a. Thus, the component information includes hierarchical configuration information.

  FIG. 8 is a diagram showing an example of manufacturing process information according to the present invention. In this example, the manufacturing process 5 requires that the manufacturing processes 1 and 3 have been completed as the previous process, the process time is 25, the part a to be used is 2, the part c is 10, and so on. It shows that there is.

  FIG. 9 is a diagram showing an example of parts inventory / ordering information according to the present invention. In this example, the part e is currently in stock 100, and there are 500 remaining orders scheduled to arrive on April 30, 2004, 100 remaining orders scheduled to arrive on May 10, 2004, and so on. .

  FIG. 10 is a diagram showing an example of manufacturing process load information according to the present invention. In this example, the load status of manufacturing process 5 on April 23, 2004 indicates that the capacity is 200 and the load on the current production plan is 180, so the load factor is 0.90.

  FIG. 11 is a diagram showing an example of component procurement lead time according to the present invention. This example shows that the lead time from ordering to delivery of the component b is 10 days.

  FIG. 12 is a diagram showing an example of the number of parts procurement lots of parts according to the present invention. This example shows that the order lot number of the part b is 100, and the like.

  Next, the operation flow of the present invention will be described with reference to FIGS.

FIG. 13 and FIG. 16 are flowcharts showing the procedure for determining acceptance of a new product order opportunity.
First, the control unit 31 of the personal computer 3 on the product manufacturer side acquires the product code, delivery date, and quantity as new product order information via the input unit 35 (S1).
Next, the control unit 31 of the personal computer 3 transmits the product code, delivery date, and quantity to the server 4 via the communication interface unit 33 (S2).
Next, the control unit 41 of the server 4 receives the product code, delivery date, and quantity via the communication interface unit 43 (S3).
Next, the control unit 41 of the server 4 determines whether product inventory can be allocated based on the product code, quantity, delivery date, and product inventory information (S4).
If the product inventory can be allocated, the control unit 41 of the server 4 reduces the desired quantity by the number of allocated product inventory (S5).
When the desired quantity becomes zero, the control unit 41 of the server 4 uses the new product order information as it is as a final acceptance determination result, and the product code, delivery date and quantity are communicated via the communication interface unit 43 to the personal information on the product manufacturer side. It transmits to the computer 3 (S6).
If the desired quantity does not become zero, the control unit 41 of the server 4 calculates the necessary quantity of lower-level parts in order to produce the product, and determines whether or not the product can be produced by allocating the parts inventory ( S7). This determination is repeated up to the end level for all parts required for product production.
If the product can be produced by the parts inventory allocation, the control unit 41 of the server 4 reduces the desired quantity by the number of parts inventory allocated (S8).
If the desired quantity becomes zero, the process proceeds to S6.
If the desired quantity is not zero, the control unit 41 of the server 4 calculates the part code, quantity and delivery date of the part that needs to be newly procured as the part procurement condition (S9). This calculation is repeated up to the end level for all parts required for product production. This calculation is performed based on the number of parts procurement lots and part procurement lead time information of the part. However, if it is necessary to shorten the part procurement lead time, the part procurement lead time is reduced and procurement is performed. Calculate as follows.
Next, the control unit 41 of the server 4 transmits the part code, quantity, and delivery date of a part that needs to be newly procured as a part procurement condition to the personal computer 3 on the part vendor side via the communication interface part 43 ( S10).
Next, the control unit 31 of the personal computer 3 on the component vendor side causes the display unit 34 to display the component code, quantity, and delivery date of the component that needs to be newly procured as the component procurement condition (S11).
Next, the control unit 31 of the personal computer 3 on the component vendor side acquires information on the quantity and delivery date of parts that can be newly delivered as update information on the component procurement conditions via the input unit 35 (S12). At this time, on the part vendor side, the delivery quantity can be input based on the quantity of parts that can be delivered at that time, regardless of the prescribed number of parts procurement lots. In addition, the delivery date can be changed to a delivery date that can be handled. This step is performed in the personal computers 3 of all parts vendors that supply parts that need to be newly procured.
Next, the control unit 31 of the personal computer 3 on the part vendor side sends the part code, quantity, and delivery date information of the parts that can be newly delivered as update information of the part procurement conditions via the communication interface unit 33. (S13). This step is performed in the personal computers 3 of all parts vendors that supply parts that need to be newly procured.
Next, the control unit 41 of the server 4 receives, via the communication interface unit 43, information on the part code, quantity, and delivery date of a part that can be newly procured as part procurement condition update information (S14). This step is performed for transmission information from the personal computers 3 of all the parts vendors that supply parts that need to be newly delivered.
Next, if it is possible to produce a product based on the received information on the part code, quantity, and delivery date of the newly procured part, the server 4 is provided for the number of parts that can be procured and produced. The control unit 41 reduces the desired quantity (S15).
Next, the control unit 41 of the server 4 transmits the product code, the delivery date, and the quantity to the personal computer 3 on the product manufacturer side via the communication interface unit 43 as a final new order acceptance determination result (S16).
Next, the control unit 31 of the personal computer 3 on the product manufacturer side receives the product code, delivery date, and quantity via the communication interface unit 33 (S17).
Next, the control unit 31 of the personal computer 3 on the product manufacturer side displays the product code, delivery date, and quantity as a result of the new order acceptance determination on the display unit (S18).

1 is a block diagram showing an overall configuration of a system according to the present invention. 2 is a block diagram showing a configuration of a personal computer 3. FIG. 3 is a block diagram showing a configuration of a server 4. FIG. It is a block diagram which shows one example of a structure of the screen display information which the control part 31 of the personal computer 3 displays on the display part 34. FIG. It is a block diagram which shows another example of a structure of the screen display information which the control part 31 of the personal computer 3 displays on the display part. It is a block diagram which shows another example of a structure of the screen display information which the control part 31 of the personal computer 3 displays on the display part. It is a figure which shows an example of the component information which concerns on this invention. It is a figure which shows an example of the manufacturing process information which concerns on this invention. It is a figure which shows an example of the stock and ordering information of the parts which concern on this invention. It is a figure which shows an example of the manufacturing process load information which concerns on this invention. It is a figure which shows an example of the lead time information which concerns on this invention. It is a figure which shows an example of the order lot number information which concerns on this invention. It is a flowchart which shows the procedure of acceptance determination of a new order. It is a flowchart which shows the procedure of acceptance determination of a new order. It is a flowchart which shows the procedure of acceptance determination of a new order.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Production management system 2 Communication network 3 Personal computer 4 Server 31 Control part 32 Storage part 33 Communication interface part 34 Display part 35 Input part 36 Bus 41 Control part 42 Storage part 43 Communication interface part 44 Display part 45 Input part 46 Bus

Claims (1)

A production management system in which a manufacturer side terminal , a parts vendor side terminal, and a server can be connected via a communication network,
The manufacturer side terminal
Display means;
Manufacturer input acceptance means,
Product order information receiving means for receiving the product code, quantity, and delivery date as new product order information that accompanies a change in the production plan;
Product order information transmitting means for transmitting the new product order information received by the product order information receiving means to the server,
The server
Storage means including at least a parts information storage area for storing the quantity of parts constituting the product as part information, a product inventory information storage area for storing product inventory information, and a parts inventory information storage area for storing part inventory information ;
Product order information receiving means for receiving the new product order information from the manufacturer side terminal ;
Based on the product code, quantity, and delivery date corresponding to the new product order information received by the product order information receiving means, and the product inventory information stored in the storage means, the product corresponding to the product code Product allocation availability determination means for determining whether allocation is possible ;
Product allocation means for allocating a product corresponding to the new product order information based on the product inventory information when the product allocation availability determination unit determines that the product allocation is possible;
When it is determined that the product is not allocated by the product allocation enable / disable determining unit, and when the product allocation unit is short of the quantity of the product allocated relative to the quantity included in the new product order information, the part information And a missing part calculation means for calculating the quantity of parts corresponding to the quantity of products not allocated,
Based on the quantity of parts calculated by the insufficient parts calculation means and the parts inventory information, a part allocation availability determination means for determining whether the calculated parts can be allocated;
When it is determined that the part can be allocated by the part allocation enable / disable determining unit, the part allocation unit that allocates the calculated part based on the part inventory information;
When it is determined that the part is not allocated by the part allocation enable / disable determining unit, and when the part allocation unit is insufficient with respect to the part quantity calculated by the insufficient component calculating unit, A component procurement condition transmission means for transmitting a part code, quantity and delivery date of a part not allocated to the component vendor side terminal as a component procurement condition;
The parts vendor side terminal is
Vendor side input acceptance means,
Parts procurement condition receiving means for receiving the parts procurement conditions from the server;
For the part corresponding to the part code included in the part procurement conditions, the vendor side input receiving means for the part code, the delivery date, and the quantity that can be delivered regardless of the delivery date and order quantity of the part specified in advance. Deliverable quantity accepting means for accepting input via
Deliverable information transmitting means for transmitting the part code, delivery date and quantity accepted by the deliverable quantity accepting means to the server as deliverable information,
The server
Deliverable information receiving means for receiving the deliverable information from the parts vendor side terminal;
Based on the deliverable information and the quantity of the product allocated by the product allocation means, the acceptance determination result for calculating the product code corresponding to the product, the newly producible quantity of the product, and the delivery date as the acceptance determination result A calculation means;
An acceptance determination result transmitting means for transmitting the acceptance determination result to the manufacturer side terminal,
The manufacturer side terminal
An acceptance determination result receiving means for receiving the acceptance determination result from the server;
A production management system further comprising: an acceptance determination result display control means for causing the display means to display the acceptance determination result.

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