JP5047929B2 - Production planning support device, method, program, and computer-readable storage medium - Google Patents

Description

  The present invention relates to a production planning support apparatus, method, program, and computer-readable storage medium for supporting a long-term production planning work before an order is received in a manufacturing industry having a process for producing a variety of small lot products in large quantities.

  For example, in the manufacturing industry such as the steel manufacturing industry, there are a wide variety of product standards and sizes, and there is an increasing demand for compliance with delivery dates and shortening delivery times according to the customer's product use schedule. On the other hand, in the manufacturing process, from the viewpoint of productivity improvement by mass production, it is required that a plurality of orders having the same manufacturing specifications such as chemical components of products in a steelmaking facility are produced in batch units.

  However, the manufacturing process is performed in a plurality of manufacturing facilities such as steel making, rolling, refining, and shipping, and the optimum lot conditions in each manufacturing facility are different. Therefore, pursuing the productivity of a lot at one manufacturing facility reduces the productivity of other manufacturing facilities, or the lot summarization in the upstream process leads to concentration of the manufacturing load in the downstream process, leading to an increase in work in progress and an increase in the manufacturing period. For example, it is required to create a lot in consideration of a trade-off between manufacturing processes. In addition, pre-fabrication for making lots causes extra product inventory and a corresponding increase in work period.

  On the other hand, in the steel industry, for example, the following orders and production management are performed. The sales department makes a demand forecast for each product type for the period (for example, half a year, quarter) according to the planned work before receiving an order, verifies the production capacity, and if there is a problem, measures for sales or steelworks We will consider and implement measures on the production side. On the other hand, after receiving an order inquiry from a customer, after accepting the order based on the manufacturing specifications, delivery date, etc. of the order and negotiating the delivery date as necessary, the order is finalized and the steelworks that is the manufacturing department Make manufacturing instructions. Steelworks will consider more detailed manufacturing specifications based on order information such as order size, quantity, delivery date, and specifications ordered by the sales department. Based on the production specifications, the production lots and production timings of each production facility are planned and production instructions are issued in consideration of the delivery date, production period, productivity in the production process, and the like.

  Although demand and production capacity are matched before ordering and at the ordering stage in this way, the complexity of the manufacturing process as described above and the complexity of handling a large variety of small lot orders in large quantities are combined. At present, it is difficult to appropriately plan and evaluate production plans that take into account the unity of lots at each manufacturing facility and the manufacturing load. In addition, after order information is instructed to the steelworks, that is, after the delivery date is confirmed, the decision of the production start timing is an important planning factor. It is necessary to allow an increase in inventory due to production, and drastic improvement in productivity by adjusting the start timing of the manufacturing process. However, there is a problem that there is a limit to shortening the construction period and reducing inventory.

  On the other hand, in Patent Document 1, in the order negotiation support method for supporting the order negotiation of a product produced by a production process having a surplus product as an inventory, the appropriation and surplus of the surplus product before the order is taken into consideration when considering the product order. Simulation of production plan taking into account the occurrence of products, and even when the order conditions are changed within a predetermined range, the same data processing is performed, so that the production plan and alternatives suitable for the customer's order conditions And a method for presenting order conditions that appropriately reflect manufacturing costs and the like are disclosed.

  In addition, in Patent Document 2, regarding the delivery date response method of the seat reservation method, the allocation change to the part seat when there is an order change is made promptly by loading the number of allocations and the seats without associating them. The method to perform is disclosed.

JP 2005-242816 A JP 2004-355302 A

  The technology described in Patent Document 1 is a method of reflecting the new order in the production schedule of the surplus product and the received order when there is an inquiry for a new order. Since information is not taken into consideration, there is a problem that it is not possible to consider the production lot and production load when the new order is actually produced.

  In addition, the technology described in Patent Document 2 is a product type that checks whether or not it can be loaded into the due date frame on a product-by-product basis and answers the delivery date. It is difficult to make a production plan for each product before receiving an order. There is a problem that it is difficult to apply to the steel industry with a complicated production process.

  The present invention solves the above problems, and in the manufacturing industry that manufactures a plurality of types of products through processing in a manufacturing process constituted by a plurality of manufacturing facilities, When a production plan for each product type that matches the demand forecast and production capacity including production lots is prepared in advance before ordering to improve throughput and reduce inventory in the manufacturing process, and there is a mismatch between the two The purpose is to be able to take such measures in advance.

The production plan planning support apparatus of the present invention is a production plan planning support apparatus for supporting a production planning process before receiving an order in a manufacturing industry that produces a large amount of various types and small lot products,
A manufacturing specification database that captures and stores manufacturing specification information in the production process for each predetermined product type,
A production load database that captures and stores production load information for each production specification,
A manufacturing period database that captures and stores manufacturing period information for each manufacturing specification,
A demand forecast information setting unit for setting a demand forecast amount for each delivery date for each product type;
By multiplying the set demand forecast amount for each delivery date for each product type by the production specification information indicating the association between the product type and the product specification read from the production specification database, the demand forecast amount for each delivery date for each production specification is obtained. A manufacturing requirement information generating unit that calculates a manufacturing requirement amount for each manufacturing specification and a manufacturing start period, by calculating and tracing back the manufacturing time for each manufacturing specification read from the manufacturing time period database;
A planning guideline setting unit for setting a guideline for production planning;
A production capacity information setting unit for setting a production capacity value of the production process;
Based on the set production planning guideline, the manufacturing requirement for each manufacturing specification is satisfied as much as possible and the set production capacity value is not exceeded, and the productivity in the production process is maximized. A production plan creation unit that creates a production plan as a production plan for each production specification for each production start period,
A production plan database that captures and stores a production plan for each production start period for each production specification;
A production plan read from the production plan database is displayed, and a production plan display correction unit in which a correction value is input as necessary;
From the production plan for each manufacturing specification read out from the production plan database, the order plan for each delivery date for each manufacturing specification is created by reducing the time for the manufacturing period for each manufacturing specification, and for each delivery date for each manufacturing specification. An order plan creation unit for creating an order quantity for each delivery date as a sales order plan by multiplying the manufacturing specification information with the order plan of
An order plan database that captures and stores an order plan for each delivery date for each product type;
An order plan display correction unit for displaying an order plan read from the order plan database and inputting a correction value as necessary;
The production plan planning support method of the present invention is a production plan planning support method for supporting a production plan planning operation before an order is received in a manufacturing industry that produces a large amount of various kinds and small lot products,
Capturing manufacturing specification information in a production process for each predetermined type and storing it in a manufacturing specification database;
Capturing manufacturing load information for each manufacturing specification and storing it in the manufacturing load database;
Capturing manufacturing period information for each manufacturing specification and storing it in the manufacturing period database;
By multiplying the demand forecast amount for each delivery date for each product type set by the production plan creator with manufacturing specification information representing the relationship between the product specifications read out from the product specification database and the manufacturing specifications, A production requirement information generation step for calculating a demand forecast amount and calculating a production requirement amount for each production start period for each production specification by going back only by the production term for each production specification read from the production term database;
Based on the production plan drafting guidelines set by the production plan creator, the production requirements for each production specification for each production start period should be satisfied as much as possible, and the production capacity of the production process set by the production plan creator should not be exceeded. And a production plan creation step for creating a production amount as a production plan for each production specification so that the productivity in the production process is maximized,
Capturing a production plan for each production start period for each production specification and storing it in a production plan database;
A production plan read from the production plan database is displayed, and a production plan display correction step in which a correction value is input as necessary;
From the production plan for each manufacturing specification read out from the production plan database, the order plan for each delivery date for each manufacturing specification is created by reducing the time for the manufacturing period for each manufacturing specification, and for each delivery date for each manufacturing specification. An order plan creation step of creating an order quantity for each delivery date as an order plan by multiplying the manufacturing specification information with the order specification plan of
Capturing an order plan for each delivery date for each product type and storing it in an order plan database;
An order plan display correction step for displaying an order plan read from the order plan database and inputting a correction value as necessary is provided.
The program of the present invention is a program for causing a computer to execute a support process of a production planning work before receiving an order in a manufacturing industry that produces a large number of various types and small lot products,
A manufacturing specification database that captures and stores manufacturing specification information in the production process for each predetermined product type,
A production load database that captures and stores production load information for each production specification,
A manufacturing period database that captures and stores manufacturing period information for each manufacturing specification,
Demand forecast information setting means for setting a demand forecast amount for each delivery date for each product type;
By multiplying the set demand forecast amount for each delivery date for each product type by the production specification information indicating the association between the product type and the product specification read from the production specification database, the demand forecast amount for each delivery date for each production specification is obtained. A production requirement information generating means for calculating a production requirement amount for each production specification period by going back by the production term for each production specification calculated and read from the production term database;
Planning guideline setting means for setting a guideline for production planning,
Production capacity information setting means for setting the production capacity value of the production process;
Based on the set production planning guideline, the manufacturing requirement for each manufacturing specification is satisfied as much as possible and the set production capacity value is not exceeded, and the productivity in the production process is maximized. Production plan creation means for creating the production volume for each production specification as a production plan for each production specification,
A production plan database that captures and stores a production plan for each production start period for each production specification;
Production plan display correction means for displaying a production plan read from the production plan database, and inputting a correction value as necessary;
From the production plan for each manufacturing specification read out from the production plan database, the order plan for each delivery date for each manufacturing specification is created by reducing the time for the manufacturing period for each manufacturing specification, and for each delivery date for each manufacturing specification. An order plan creation means for creating an order quantity for each delivery date as a order plan by multiplying the manufacturing specification information with the order plan of
An order plan database that captures and stores an order plan for each delivery date for each product type;
The order plan read from the order plan database is displayed, and the computer is made to function as an order plan display correcting means for inputting correction values as necessary.
The computer-readable storage medium of the present invention stores the program of the present invention.

  According to the present invention, based on the demand prediction and the past manufacturing results, the production plan for each product type is made in consideration of the sales, the evaluation index for manufacturing, and the constraint conditions. This makes it possible to plan in advance a steel process production plan that produces a large quantity of small-lot products in large quantities, taking into account the needs of both customers and manufacturing, and there is a problem in terms of delivery. Can take measures against sales and production at an early stage, and as a result, improve the accuracy of product delivery to customers.

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.
First, an example of a schematic configuration of a manufacturing process of a thick steel plate (thick plate) that is a typical product in the steel industry will be described with reference to FIG. In FIG. 3, the arrows indicate the flow of work in progress.

  In the converter 101, a steel output component, which is a chemical component of a steel intermediate product (molten steel) in a high-temperature molten state, is adjusted in units of, for example, about 300 [ton], and is discharged into a molten steel pan. The steel output unit in the converter 101 is called charge.

  The continuous casting equipment 102 continuously casts molten steel produced in the converter 101 for a plurality of charges and then cuts it to a specified length, for example, a plate-like intermediate product called a slab of about 20 [ton] units. Manufacturing. A series of production units in the continuous casting facility 102 is called casting. Although it depends on the manufacturing specifications, the 8 to 12 charges are manufactured as one cast.

  In the rolling equipment 103, the slab is heated and then formed to a predetermined thickness and width. The refining (cutting) equipment 104 cuts to the size of the custom specification, the refining (correction) equipment 105 performs correction to ensure the quality of the shape and the like, and the refining (care) equipment 106 ensures quality. Products that have undergone care and have undergone all processing are placed in the warehouse 107. A product cut to the size of the custom specification is called a plate.

  Table 1 shows an example of the size (unit) of a typical minimum production lot in each production facility of the thick plate production process. In this example, the converter 101 is about 100 times the size of the final product (minimum production lot in the warehouse) 3 [ton], and the continuous casting equipment 102 is about 800 times the size of the final product. Manufacturing as a manufacturing lot unit is necessary from the viewpoint of productivity and yield.

  However, if priority is given to the productivity and yield of converters and continuous casting machines, and if the delivery date is made up to the previous order and the production lot is increased, there is a problem that the product inventory increases. Moreover, if the production lot of a converter or a continuous casting machine is increased without considering the production load of the finishing equipment 104 to 106, it will lead to an increase in the work due to concentration of the production load and an increase in the production period. That is, it is also important to equalize the manufacturing load in each manufacturing apparatus.

  In this way, it is important to formulate a production plan for a continuous casting machine at the start of production so that the conflicting issues of expansion of production lots and leveling of production load are compatible, but after the delivery date is fixed Since the adjustment of the manufacturing start timing at this time leads to variations in the manufacturing completion timing, it becomes a bottleneck in shortening the construction period until delivery to the customer.

  The aim of the present invention is to develop a production plan by product type that matches the demand forecast and production capacity including production lots in order to improve the accuracy of the delivery time of orders, improve the throughput in the manufacturing process, and reduce inventory. It is to plan in advance before receiving an order and to take measures against them in the event of a mismatch between the two.

  In order to solve this problem, the present invention creates a production plan for each product type based on the demand forecast information for each product type, the demand forecast information for each delivery date, and the operation schedule information for the production process. Assess consistency with capabilities. That is, in the present invention, based on the demand prediction and production capacity information, a production plan for each product type that satisfies the requirements to be satisfied by the production process such as expansion of production lots and production load leveling is prepared in advance before receiving an order. And quantitative evaluation of productivity, delivery date compliance, etc. makes it possible to clarify the location of problems.

  FIG. 1 shows a schematic configuration of a production plan creation support apparatus according to the present embodiment. Information necessary for producing the production plan is stored in the manufacturing specification database D1, the manufacturing load database D2, and the manufacturing work period database D3. These databases are described below.

  In the manufacturing specification database D1, results (manufacturing specification information) obtained by calculating the manufacturing specifications on the production line for each product type, which is a unit for demand prediction, based on past manufacturing performance data are captured and stored and held. . As manufacturing specifications, items to be evaluated at the time of production plan preparation are considered. In the present embodiment taking the steel industry as an example, the production specifications of the production specification database D1 have as factors the steel output component in the steel making process and the production load of each process after the rolling process.

  In the manufacturing load database D2, results (manufacturing load information) obtained by calculating the manufacturing load in each manufacturing process for each manufacturing specification based on past manufacturing performance data are captured, stored, and held. The manufacturing process considers a manufacturing process that should consider the manufacturing load when creating a production plan.

  In the manufacturing period database D3, a result (manufacturing period information) obtained by calculating the manufacturing period for each manufacturing specification based on the past manufacturing result data is captured and stored and held.

  In the demand forecast information setting unit 1, the plan creator predicts and sets the demand forecast amount for each delivery date for each product type based on the past demand record and the quantity forecast information from the customer.

  The production request information generation unit 2 multiplies the demand forecast amount for each delivery date set by the demand forecast information setting unit 1 by the production specification information indicating the association relationship between the product type and the production specification read from the production specification database D1. By combining them, the demand forecast amount for each delivery date of each production specification is calculated, and the production requirement amount for each production start date for each production specification is calculated by going back by the production term for each production specification read from the production term database D3.

  The planning guideline setting unit 3 sets a guideline when the plan creator makes a production plan. In the production capacity information setting unit 4, the plan creator sets the production capacity value of the production process.

  Based on the production plan drafting guide set by the planning guide setter 3, the production plan creation unit 5 satisfies the production requirement for each manufacturing specification for each manufacturing start period as much as possible, and the production set by the production capacity information setter 4. The production amount for each production specification is drafted as a production plan so as not to exceed the capacity value and maximize the productivity in the production process.

  The production plan database D4 captures and stores the production plan for each production specification created by the production plan creation unit 5 for each production start period.

  The production plan display correction unit 6 displays the production plan read from the production plan database D4, and a correction value is input as necessary.

  The order plan creation unit 7 creates an order plan for each delivery date of each production specification from the production plan for each production specification read from the production plan database D4 by reducing the manufacturing period for each production specification. Then, by multiplying the production specification information by the order receipt plan for each delivery date for each production specification, the order quantity for each delivery date for each product type is created as an order receipt plan.

  The order plan database D5 captures and stores the order plan for each delivery date created by the order plan creation unit 7.

  The order plan display correction unit 8 displays the order plan read from the order plan database D5, and a correction value is input as necessary.

  FIG. 2 shows an outline of a production plan creation procedure by the production plan planning support apparatus according to the present embodiment. The production plan creator inputs and sets the demand forecast amount for each delivery date for each product type from the demand forecast information setting unit 1 (step S1 in FIG. 2).

  The production request information generating unit 2 reads the demand forecast amount for each delivery date set by the demand forecast information setting unit 1, the production specifications for each product type read from the production specification database D1, and the production period database D3. Based on the produced manufacturing period information for each production specification, a required amount for each production specification is calculated (step S2 in FIG. 2).

  The production plan maker inputs and sets the planning guidelines for the evaluation indexes in the production planning such as the size of the manufacturing lot, the manufacturing load leveling degree, and the delivery date compliance from the planning guide setting unit 3 (step S3 in FIG. 2). ). In addition, the production plan creator inputs and sets production capacity information such as the production capacity upper limit value of the production equipment and the operation plan of each production equipment during the planning period from the production capacity information setting unit 4 (step S4 in FIG. 2). ).

  The production plan creation unit 5 includes the production request information generated by the production request information generation unit 2, the planning guidelines set by the planning guide setting unit 3, the production capacity information set by the production capacity information setting unit 4, and Based on the manufacturing load information for each manufacturing specification read from the manufacturing load database D2, the production amount for each period for each manufacturing specification is calculated (step S5 in FIG. 2).

  The production plan display correction unit 6 displays the planned production plan on a display device such as a display, and the production plan creator evaluates the displayed plan, corrects it as necessary, and confirms it (FIG. 2). Step S6). The production planner evaluates the displayed production plan (step S7 in FIG. 2), and returns to the planning guideline setting step (step S3 in FIG. 2) when determining that re-planning is necessary.

  If it is determined that the re-planning is unnecessary, the order receiving plan creating unit 7 reads the manufacturing specification information read from the manufacturing specification database D1, the manufacturing lead information read from the manufacturing lead database D3, and the production plan read from the production plan database D4. Based on the information, an order plan for each product type is created (step 8 in FIG. 2).

  The order plan display correction unit 8 displays the order plan on a display device such as a display, and the production plan creator evaluates the displayed plan, corrects it as necessary, and confirms (step S9 in FIG. 2). ).

Next, an example of production plan creation will be described. The production plan creator receives a demand forecast amount s _{ref — nj} [with a product type n and a period j from the demand forecast information setting unit 1 including information input means such as a keyboard, an electronic file drive, and a network I / O. ton]. Table 2 shows numerical values in this example.

Next, the production requirement information generation unit 2 uses the production specification RATIO_N _in representing the relationship between the product type n and the production specification i read from the production specification database D1, and determines the demand forecast amount by product type for the production specification i and the period j. It is converted into a demand forecast amount by manufacturing specification x _{eref — ij} [ton] as a delivery date. Formula (1) shows the conversion formula.

Table 3 shows the manufacturing specification RATIO_N _{in in} this example.

Equation (2) is a manufacturing period model that relates manufacturing specifications i, the tapping amount target x _sref _ _ij period j and manufacturing specifications Demand forecast quantity x _eref _ _ij.

Here, f _i (β _i ) is the manufacturing period of the manufacturing specification i, and β _i is a target value of the assortment achievement rate of the manufacturing specification i. f _i (β _i ) is modeled using the manufacturing flow in the manufacturing specification, the past manufacturing period results, and the like. Note that the manufacturing period for each manufacturing specification in this example is all three for simplicity.

Tapping component m, the tapping amount z_ _mj period j is manufacturing specifications i as in Equation (3), the tapping plan amount x _s _ _ij period j, manufacturing specifications i, the composition ratio of the tapping component m It expressed as multiplied by RATIO_C _im. Here, RATIO_C _im is manufacturing specifications i, the composition ratio of the tapping component m [-] a and, next RATIO_C _im = 1 when tapping component manufacturing specifications i is m, RATIO_C _im at other times = 0. Incidentally, if it contains more tapping component manufacturing specifications i is 0 <a RATIO_C _im <1. Table 4 shows numerical examples in this embodiment.

Equation (4) is manufacturing equipment k, and represents the constraints on processing amount y_ _kj of the period j, it is a constraint on manufacturing is set based on the maximum processing capacity and the estimated activation facilities. Here, y_ _kj _ _max manufacturing facility k, the processing amount upper limit value of the period j [ton], Δy_ _kj manufacturing facility k, the processing amount upper limit value was exceeded amount of processing in the period j the [ton], CAP_ _k the equipment on the processing amount upper limit value of the manufacturing facility k [ton], and OPR_ _kj is representative of the estimated activation rate in period j manufacturing equipment k [%]. If excess processing amount Derutawai_ _kj is positive it becomes correspondingly progress, so that the construction period is prolonged. The numerical value of the processing amount upper limit value y_ _kj _ _max in this example are shown in Table 5. Processing amount upper limit value y_ _kj _ _max is set from capacity information setting section 4.

Equation (5), the sum of the production equipment k, is the amount of processing y_ _kj in the period j manufacturing specifications by tapping plan amount x _s _ _ij in manufacturing specifications i, all manufacturing specifications of those multiplied by the occurrence rate of the manufacturing equipment k It represents that. Here, RATIO_O_ _ik manufacturing specifications i, the incidence of production facilities k [-] is, is set by reading from the manufacturing load database D2. I is the number of manufacturing specifications. Table 6 shows numerical values of the incidence rates in this example.

Equation (6), manufacturing specifications i, and tapping plan amount x _s _ _ij of the period j, manufacturing specifications i, of the tapping plan the amount of period j, order quantity tapping demand date is r x _s _ _This is an expression representing the relationship with _irj .

Equation (7) is an evaluation index for directing the tapping component m, the tapping amount z_ _mj period j is an integer multiple of the tapping unit LOT_SIZE _m of tapping component m. Here, δ_ _mj is an integer of 0 or more, M is the number of tapping component. In this embodiment, LOT_SIZE _m is all 2,400 [ton].

Equation (8), manufacturing facility k, by minimizing the amount of processing Derutawai_ _kj in excess processing amount upper limit value of the period j, is an evaluation index that directs the minimization of in-process in the production facility k.

  Expression (9) is an evaluation index that aims to minimize the shortage of the production frame with respect to the processing plan amount of the rolling equipment 103.

  Expression (10) is an evaluation index that is aimed at minimizing the deviation between the steel output request date and the steel output planned date.

When the weighted linear sum of the evaluation indexes (7) to (10) is taken, a comprehensive evaluation index (11) in which the evaluation indexes are balanced is obtained. Here, w ₁ , w ₂ , w ₃ , and w ₄ are relative evaluation weights for deviation from the steel output component summary deficiency, production facility throughput excess, rolling deficiency deficiency, and output date. Yes, it is set by the planning guideline setting unit 3 according to the strategy at the time of production frame planning.

In summary, the production plan creation unit 5 calculates a steel production planned amount x _{s — ij} for each production specification that satisfies the expressions (1) to (6) and minimizes the comprehensive evaluation index (11). That is, the production amount of each steel output component in the steelmaking process is as close as possible to an integral multiple of the minimum unit determined in advance for each steel output component, and the shortage of the production frame with respect to the processing plan amount of the rolling process is as small as possible. In addition, a production plan for each period of each production specification is created for a predetermined period so that the production load after the rolling process is within the production capacity and the deviation from the production request period for each steel output component is minimized. Table 7 shows the planned steel production amount x _{s — ij} for each production specification in this example.

If Motomare manufacturing specifications by tapping plan amount x _s _ _ij, Equation (5) the manufacturing facility by the processing amount y_ _kj [ton] using formula (3) tapping component by tapping amount using the z_ _mj can be calculated. In addition, the planned shipping quantity x _{e — ij} is calculated using Expression (12).

It may be appropriately used solver like commercial mathematical programming method in the calculation of the manufacturing specifications by tapping plan amount x _s _ _ij. The manufacturing facility by processing amount y_ _kj in Table 8 in the present embodiment, the tapped components by tapping amount z_ _mj Table 9 shows the manufacturing specifications Shipment planned amount x _e _ _ij in Table 10.

Next, a method for calculating the planned shipment quantity S _{e — nj} for the product type n and the period j from the planned steel production quantity by production specification x _{s — ij} will be described.

At the time of manufacturing specifications by tapping plan amount x _s _ _ij calculated, from the relationship of the equation (6), the amount of tapping demand Daily of tapping plan x _s _ _irj is also calculated at the same time. Using the manufacturing period model f _i (β _i ), the shipping plan amount x _{e — irj} in the order period j with the manufacturing specification i and the delivery date r is calculated by the equation (13).

Next, a linking matrix for each delivery date relating to which kind of shipment corresponds to the shipment planned amount x _{e _irj for} each manufacturing specification is calculated. First, by multiplying the demand amount (delivery request amount) for each delivery date by the association matrix RATIO_N _in between the product type and the production specification, an association relationship equation (14) between the production specification and the product type is obtained for each shipment date. .

  Then, as shown in the equation (15), the pegging relational equation (14) is normalized for each manufacturing specification, thereby calculating a pegging matrix for each delivery date.

Then, the shipping planned amount S _{e — nj} for each product type is calculated using Equation (16).

  Table 11 shows the planned shipment amount for each product type in this example.

  From Table 8, it can be seen that a plan that does not exceed the capacity of the refining equipment can be drawn up while making maximum use of the steelmaking and rolling capacity. Moreover, it can be seen from Table 9 that the amount of steel output of the same steel output component is the unit of charge (300 [ton]). Moreover, it can be seen from Tables 2 and 11 that a plan can be made for each product type without delaying the delivery date.

  The object of the present invention is to supply a storage medium storing software program codes for realizing the functions of the above-described embodiments to a system or apparatus, and the computer (CPU or MPU) of the system or apparatus is stored in the storage medium. Needless to say, this can also be achieved by reading and executing the program code.

  In this case, the program code itself read from the storage medium realizes the functions of the above-described embodiments, and the storage medium storing the program code constitutes the present invention.

  As a storage medium for supplying the program code, for example, a flexible disk, a hard disk, an optical disk, a magneto-optical disk, a CD-ROM, a CD-R, a magnetic tape, a nonvolatile memory card, a ROM, or the like can be used.

  Further, by executing the program code read by the computer, not only the functions of the above-described embodiments are realized, but also an OS (operating system) or the like running on the computer based on the instruction of the program code. It goes without saying that a case where the function of the above-described embodiment is realized by performing part or all of the actual processing and the processing is included.

  Further, after the program code read from the storage medium is written into a memory provided in a function expansion board inserted into the computer or a function expansion unit connected to the computer, the function expansion is performed based on the instruction of the program code. It goes without saying that the CPU or the like provided in the board or the function expansion unit performs part or all of the actual processing and the functions of the above-described embodiments are realized by the processing.

It is a figure which shows schematic structure of the production plan planning assistance apparatus which concerns on embodiment of this invention. It is a flowchart which shows the outline of the preparation procedure of the production plan by the production plan planning assistance apparatus which concerns on embodiment of this invention. It is the schematic of an example of the thick board manufacturing process in the steel industry.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Demand prediction information setting part 2 Manufacturing prediction information generation part 3 Planning guideline setting part 4 Production capacity information setting part 5 Production plan preparation part 6 Production plan display correction part 7 Order plan preparation part 8 Production plan display correction part 101 Converter 102 Continuous Casting 103 Rolling 104 Refinement (cutting)
105 Refinement (correction)
106 Refinement (care)
107 Warehouse D1 Manufacturing specification database D2 Manufacturing load database D3 Manufacturing work schedule database D4 Production planning database D5 Order planning database

Claims (7)

A production planning support device for supporting production planning work prior to ordering in a manufacturing industry that produces a large number of various types and small lot products,
A manufacturing specification database that captures and stores manufacturing specification information in the production process for each predetermined product type,
A production load database that captures and stores production load information for each production specification,
A manufacturing period database that captures and stores manufacturing period information for each manufacturing specification,
A demand forecast information setting unit for setting a demand forecast amount for each delivery date for each product type;
By multiplying the set demand forecast amount for each delivery date for each product type by the production specification information indicating the association between the product type and the product specification read from the production specification database, the demand forecast amount for each delivery date for each production specification is obtained. A manufacturing requirement information generating unit that calculates a manufacturing requirement amount for each manufacturing specification and a manufacturing start period, by calculating and tracing back the manufacturing time for each manufacturing specification read from the manufacturing time period database;
A planning guideline setting unit for setting a guideline for production planning;
A production capacity information setting unit for setting a production capacity value of the production process;
Based on the set production planning guideline, the manufacturing requirement for each manufacturing specification is satisfied as much as possible and the set production capacity value is not exceeded, and the productivity in the production process is maximized. A production plan creation unit that creates a production plan as a production plan for each production specification for each production start period,
A production plan database that captures and stores a production plan for each production start period for each production specification;
A production plan read from the production plan database is displayed, and a production plan display correction unit in which a correction value is input as necessary;
From the production plan for each manufacturing specification read out from the production plan database, the order plan for each delivery date for each manufacturing specification is created by reducing the time for the manufacturing period for each manufacturing specification, and for each delivery date for each manufacturing specification. An order plan creation unit for creating an order quantity for each delivery date as a sales order plan by multiplying the manufacturing specification information with the order plan of
An order plan database that captures and stores an order plan for each delivery date for each product type;
A production plan planning support apparatus, comprising: an order plan display correction unit that displays an order plan read from the order plan database and receives a correction value as needed.   2. The manufacturing specification is created based on a production amount actual value for each past production specification for each product type, and the manufacturing term is calculated based on a manufacturing term actual value for each past production specification. The production planning support device described.   The manufacturing industry is an iron and steel industry, and the manufacturing specifications of the manufacturing specification database have a steel load component in a steel making process and a manufacturing load of each process after the rolling process as elements. The production planning support device described.   The production plan creation unit is as close as possible to the integral multiple of the minimum unit determined for each steel output component in the steelmaking process for each period of the steel output component, and the production capacity is insufficient for the processing plan amount of the rolling process. A period in which the production plan for each production specification period is set in advance so that the amount is as small as possible, the production load after the rolling process is within the production capacity, and the deviation from the production request period for each steel output component is as small as possible. The production planning support device according to claim 3, wherein the production planning support device according to claim 3 is created. A production planning support method for supporting production planning work prior to ordering in a manufacturing industry that produces a large amount of various products and small lot products,
Capturing manufacturing specification information in a production process for each predetermined type and storing it in a manufacturing specification database;
Capturing manufacturing load information for each manufacturing specification and storing it in the manufacturing load database;
Capturing manufacturing period information for each manufacturing specification and storing it in the manufacturing period database;
By multiplying the demand forecast amount for each delivery date for each product type set by the production plan creator with manufacturing specification information representing the relationship between the product specifications read out from the product specification database and the manufacturing specifications, A production requirement information generation step for calculating a demand forecast amount and calculating a production requirement amount for each production start period for each production specification by going back only by the production term for each production specification read from the production term database;
Based on the production plan drafting guidelines set by the production plan creator, the production requirements for each production specification for each production start period should be satisfied as much as possible, and the production capacity of the production process set by the production plan creator should not be exceeded. And a production plan creation step for creating a production amount as a production plan for each production specification so that the productivity in the production process is maximized,
Capturing a production plan for each production start period for each production specification and storing it in a production plan database;
A production plan read from the production plan database is displayed, and a production plan display correction step in which a correction value is input as necessary;
From the production plan for each manufacturing specification read out from the production plan database, the order plan for each delivery date for each manufacturing specification is created by reducing the time for the manufacturing period for each manufacturing specification, and for each delivery date for each manufacturing specification. An order plan creation step of creating an order quantity for each delivery date as an order plan by multiplying the manufacturing specification information with the order specification plan of
Capturing an order plan for each delivery date for each product type and storing it in an order plan database;
A production plan planning support method comprising: an order plan display correction step for displaying an order plan read from the order plan database and inputting a correction value as required. A program for causing a computer to execute a support process for a production planning process before receiving an order in a manufacturing industry that produces a large quantity of small-lot products.
A manufacturing specification database that captures and stores manufacturing specification information in the production process for each predetermined product type,
A production load database that captures and stores production load information for each production specification,
A manufacturing period database that captures and stores manufacturing period information for each manufacturing specification,
Demand forecast information setting means for setting a demand forecast amount for each delivery date for each product type;
By multiplying the set demand forecast amount for each delivery date for each product type by the production specification information indicating the association between the product type and the product specification read from the production specification database, the demand forecast amount for each delivery date for each production specification is obtained. A production requirement information generating means for calculating a production requirement amount for each production specification period by going back by the production term for each production specification calculated and read from the production term database;
Planning guideline setting means for setting a guideline for production planning,
Production capacity information setting means for setting the production capacity value of the production process;
Based on the set production planning guideline, the manufacturing requirement for each manufacturing specification is satisfied as much as possible and the set production capacity value is not exceeded, and the productivity in the production process is maximized. Production plan creation means for creating the production volume for each production specification as a production plan for each production specification,
A production plan database that captures and stores a production plan for each production start period for each production specification;
Production plan display correction means for displaying a production plan read from the production plan database, and inputting a correction value as necessary;
From the production plan for each manufacturing specification read out from the production plan database, the order plan for each delivery date for each manufacturing specification is created by reducing the time for the manufacturing period for each manufacturing specification, and for each delivery date for each manufacturing specification. An order plan creation means for creating an order quantity for each delivery date as a order plan by multiplying the manufacturing specification information with the order plan of
An order plan database that captures and stores an order plan for each delivery date for each product type;
A program for causing a computer to function as an order plan display correcting means for displaying an order plan read from the order plan database and inputting correction values as necessary.   A computer-readable storage medium storing the program according to claim 6.

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