JP5056962B2 - Sales production delivery system and sales production delivery method for steel strip products - Google Patents

Description

  The present invention relates to a sales production and delivery system and a sales production and delivery method for steel sheet steel strip products.

  As a form of material supply that is generally known, <1> For example, steel sheets for automobiles, although there are fluctuations due to sales until model change performed at a pitch of several years, there are basically repeated orders. <2> For example, like a building member / part, it is used only for a specific purpose, and is roughly classified into a quantity and a delivery date that are not repeatedly received. The material / member / part according to the former order receiving mode is referred to as a so-called “repeat product”, and the material / member / part according to the latter order receiving mode is referred to as a so-called “spot product”.

  Here, for spot products, the order quantity and delivery date are uniformly determined by the specification design and process schedule of the property, whereas for repeat products, the specifications of the parts are determined, but the usage and delivery time are Is determined by a monthly production plan of a product using the part, and the order and production are repeated every month.

  Conventionally, with regard to the production of repeat products, as described in, for example, Japanese Patent No. 2847276 “Delivery Management System for Coiled Products”, orders for each type of specification parts are consolidated at the head office, A method is known in which an appropriate number of days or an appropriate amount of inventory is determined, a shortage with respect to the appropriate inventory is determined every season in light of the customer's use schedule, and the delivery date and order quantity are set.

  As mentioned above, the headquarters collects orders for the same specification parts, determines the appropriate inventory days or the appropriate inventory quantity for each of the same specification parts, determines the shortage of the appropriate inventory every season according to the customer's use schedule, In the conventional method of setting the delivery date and the order quantity, there are problems as listed below as (a) to (d).

  (A) If production is performed as ordered by the customer, temporary excess or deficiency may occur due to production capacity.

  Therefore, it is common practice to have an appropriate product inventory and to absorb the excess and deficiency of production with the inventory, aiming to level the operation of the production line. For this reason, orders were once aggregated at the head office, the production capacity and the order quantity were allocated, and the business step of determining the delivery date in consideration of the product inventory was generated. This requires a pool of seasonal orders at the shortest, and requires a paper lead time of approximately 10 days (paper processing waiting period: that is, the time required from the provisional order entry to the start of production (steel production)). It was.

  (B) In the method of calculating the shortage with respect to the appropriate inventory in the unit of season and setting it as the order quantity, the production lot and the order quantity cannot be matched, and an excess product is generated or a lead time waiting for a production chance is generated. Inconvenience occurred.

  (C) Variations in customer use schedules and actual results, as well as manufacturing variations, are due to factors that fluctuate in units of several months, such as fluctuations in the shipping tendency due to changes in market conditions, operational and quality stability, and changes in product inspection standards. , It changes for every unit used parts of the same kind. Therefore, there has been a problem that the proper stock setting gradually deviates from the actual situation when it is set to a fixed value.

  (D) Since the delivery date is set together at the seasonal pitch, the change in the customer's use schedule will be reflected in the seasonal unit, and the sales / trading company and the factory will secure the product coil due to the change in the customer's use schedule. The management was duplicated, and the business situation was inefficient.

  Therefore, in view of the above-mentioned points, the main object of the present invention is to set the order quantity consistent with the production lot for each steel material unit and the appropriate production start time, and to achieve short lead time production and low operation linked with customer take-off. The purpose is to provide a sales production and delivery system and a sales production and delivery method for steel sheet steel strip products that make inventory possible.

  Another object of the present invention is to input customer take-up schedule information and product inventory information directly into the terminal device of the factory, calculate the delivery date at the factory, and optimize the product inventory by the learning control method. It is to provide a sales production delivery system and a sales production delivery method for steel plate steel strip products.

  In order to achieve the above object, the sales production delivery system according to claim 1 includes a customer take-up schedule information storage means for storing information on a customer take-up schedule related to a steel plate product while updating the information to the latest state. (For example, corresponding to 412 in FIG. 2), sales order storage means (for example, corresponding to 411 in FIG. 2) for storing information on ordering of steel plate steel strip products from customers and product specifications, and production start Results information storage means (for example, equivalent to 414 in FIG. 2) for storing the actual results of fluctuations in lead time from manufacturing to completion and the actual results of the difference between the delivery deadline date and the actual delivery date for each of the same specification parts and delivery route units. ) And statistically evaluate the divergence between the target and performance for each similar specification part / delivery route using the performance information stored in the performance information storage means. The inventory days setting means (for example, corresponding to 423 in FIG. 2) for sequentially updating the appropriate inventory days setting standard by the control method, and the appropriate inventory days setting criteria (for example, FIG. 2 of FIG. 2) updated by the inventory days setting means. And a set inventory days diagnosis means (for example, corresponding to 425 in FIG. 2) for instructing an alarm to be issued when the difference between the target and the result exceeds a predetermined value. The manufacturing / distribution cost is minimized based on the take-up schedule stored in the customer take-up schedule information storage means and the take-out scale calculated based on the take-out record and / or the presence or absence of repeatability. Production order quantity determining means (for example, corresponding to 421 in FIG. 2) for determining the production order quantity per operation, and work-in-progress inventory, product inventory, and customer collection schedule for each production order Based on the appropriate inventory days setting standard updated by the inventory days setting means based on the estimated missing item occurrence date, the delivery preparation completion reference date, the production completion reference date, each manufacturing process A reference date calculation means (for example, corresponding to 422 in FIG. 2) for calculating all or some reference dates for the processing reference date, the production start instruction reference date, and output information from the reference date calculation means; Production order storage means (for example, corresponding to 426 in FIG. 2) for storing information relating to production management including at least one of product manufacturing specifications, delivery deadline date, and production completion deadline date; A production lot aggregating means (e.g., corresponding to 431 in FIG. 2) for inputting the information and aggregating production orders within a range that satisfies the production completion reference date according to the lot of the production process; Based on the output of the production lot aggregating means, a manufacturing order having the manufacturing start instruction reference date that matches the manufacturing start instruction period of the day is extracted, and manufacturing start instructing means (for example, 432 and 433 in FIG. Corresponding to the above).

  The present invention according to claim 2, in the sales production delivery system according to claim 1, further hinders delivery including any one of the following: proper inventory cracking, monthly level difference scheduled to be taken over, deviation between scheduled take-up and actual results An alarm transmission means (for example, corresponding to 440 in FIG. 2) is provided for capturing a change and transmitting an alarm to each related department.

  According to a third aspect of the present invention, in the sales production delivery system according to the first aspect, the sales order, the manufacturing order, the work in progress, and the actual product are grouped by product specification, manufacturing specification, and transportation route, Grouping processing means (for example, output corresponding data to sales order storage means, customer take-up schedule information storage means, performance information storage means, and inventory database storage means (for example, corresponding to 413 in FIG. 2)) , Corresponding to 410 in FIG.

  In the sales production delivery system according to claim 1, the present invention according to claim 4 sets an allowable range of the delivery preparation completion reference date, and aggregates products having the same transportation route to distribution bases within the allowable range. By transporting, the product transportation lot is optimized in relation to the delivery preparation completion deadline, and the loading rate of transportation per time, that is, the product amount ÷ the maximum loading amount is increased.

  According to the fifth aspect of the present invention, in the sales production delivery system according to the fourth aspect, in order to optimize the product transport lot, a customer acceptance restriction is taken into account when an order specification is added (for example, corresponding to 350 in FIG. 1). The product unit weight permissible range is set, and in the manufacturing order amount determination means (for example, equivalent to 421 in FIG. 2), the unit weight attainment level is set higher within the permissible range by using the unit weight attainment evaluation formula. Control to maintain.

  According to the sixth aspect of the present invention, in the sales production delivery system according to the fourth aspect, in optimizing the product transportation lot, in the production lot aggregation means (for example, corresponding to 431 in FIG. 2), the rare transportation is performed. By assembling the route products for each transportation lot unit based on the delivery preparation completion reference date and instructing the start of production, the product assortment in accordance with the transportation lot is guaranteed.

  The sales production delivery method according to claim 7 is a customer take-off schedule information storage step (e.g., equivalent to 412 in FIG. 2) that stores information on the take-up schedule of the customer related to the steel strip product while updating it to the latest state. A sales order storage step (for example, corresponding to 411 in FIG. 2) for storing information on ordering and product specifications of steel sheet steel strip products from customers, and fluctuations in lead time from the start of manufacturing to the completion of manufacturing. Information storage step (for example, corresponding to 414 in FIG. 2), and the result information storage step for storing the actual results and the actual results of the difference between the delivery deadline date and the actual delivery date for each of the same specification part / delivery route unit Is used to statistically evaluate the difference between the target and actual performance for each type of specification part / delivery route, and based on the actual performance, Inventory days setting step (for example, corresponding to 423 in FIG. 2) for sequentially updating the days setting standard, and appropriate inventory days setting criteria (for example, corresponding to 428 in FIG. 2) updated in the inventory days setting step. The set inventory days diagnosis step (for example, corresponding to 425 in FIG. 2) for instructing the alarm transmission for the case where the difference between the target and the result exceeds a predetermined value, Production order quantity per production that minimizes production / distribution costs based on the taking-out schedule stored in the schedule information storage step and the taking-out scale calculated based on the taking-out record and / or repeatability Production order amount determination step (for example, corresponding to 421 in FIG. 2), and in-process inventory, product inventory, and customer takeover schedule for each production order Based on the appropriate inventory days setting standard updated at the inventory days setting step from the estimated missing item occurrence date, the delivery preparation completion reference date, the production completion reference date, and each manufacturing process A reference date calculating step (for example, corresponding to 422 in FIG. 2) for calculating all or some reference dates for the processing reference date and the production start instruction reference date, and input calculation information in the reference date calculating step; A manufacturing order storage step (for example, corresponding to 426 in FIG. 2) for storing information related to production management including at least one of the product manufacturing specification, delivery deadline date, and manufacturing completion deadline date, and storage by the manufacturing order storage step A production lot aggregating step (for example, 4 in FIG. 2) that collects production orders within a range that reads the information and satisfies the production completion reference date according to the lot of the production process 31) and a manufacturing start instruction step for extracting a manufacturing order having the manufacturing start instruction reference date that matches the manufacturing start instruction period of the day based on the output of the manufacturing lot aggregation step and instructing the start of manufacturing. For example, it corresponds to 432 and 433 in FIG.

  As described above, according to the present invention, it is possible to achieve short lead-time production and low inventory in conjunction with customer take-up by setting the order quantity consistent with the production lot for each steel unit and the appropriate production start time. Can be.

  Furthermore, according to the present invention, it is possible to directly input customer take-up schedule information and product inventory information to the terminal device of the factory, calculate the delivery date at the factory, and optimize the product inventory by the learning control method. .

BRIEF DESCRIPTION OF THE DRAWINGS It is the whole block diagram which showed the relationship between the sales production delivery system of the steel plate steel strip product to which this invention is applied, and the customer and trading company relevant to this sales production delivery system. It is a detailed internal block diagram of the sales production delivery system 10 shown in FIG. It is explanatory drawing which showed the specific example of the data stored in each database (DB) memory | storage part. It is explanatory drawing which showed the specific example of the data stored in each database (DB) memory | storage part. In order to explain the operation of the grouping processing unit 410, it is an explanatory diagram illustrating a grouping key. It is explanatory drawing of the learning control operation | movement by the stock days setting process part 423. FIG. It is explanatory drawing of the learning control operation | movement by the stock days setting process part 423. FIG. 6 is an operation explanatory diagram of a manufacturing order amount determination processing unit 421. FIG. It is the flowchart which showed the process sequence for determining manufacturing order amount. It is explanatory drawing which showed the view for the reference date calculation in the reference date calculation process part 422. FIG. 5 is a flowchart illustrating a processing procedure in a reference date calculation processing unit 422. It is explanatory drawing which showed how to collect the manufacturing lot in the manufacturing lot aggregation process part 431. FIG. It is explanatory drawing which showed the procedure of the manufacture start instruction | indication by the capability verification process part 432 and the manufacture start selection process part 433. FIG. It is operation | movement explanatory drawing of the stock days diagnosis process part. It is explanatory drawing which showed the concept and operation | movement of the delivery diagnosis (diagnosis in case product inventory amount is insufficient) in the delivery diagnosis process part 424. FIG. It is explanatory drawing which showed the concept and operation | movement of the delivery diagnosis in the delivery diagnosis process part 424 (diagnosis when a product + work-in-process inventory is insufficient or the unshipped remainder is insufficient). It is explanatory drawing which showed an example of the delivery diagnosis result. FIG. 18 is an explanatory diagram of the operation of the alarm transmission processing unit 440 shown in FIG.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is an overall configuration diagram showing a sales production / delivery system of steel sheet steel strip products to which the present invention is applied and the relationship between customers and trading companies related to the sales production / delivery system. In this figure, 2 shows the whole customer who is a consumer. Here, 110 is a customer ordering section, and 120 is an inside section. Since the ordering unit 110 and the introductory unit 120 execute general ordering functions and introductory functions, detailed description thereof is omitted.

  Reference numeral 4 denotes the entire trading company, a sales order input unit 210 that outputs a sales order to the factory side, a take-up schedule input unit 220 that outputs acquisition schedule information to the factory side, and an alarm receiving unit issued from the factory side 230. The alarm issued from the factory will be described in detail later.

  6 shows the overall configuration of the factory having the sales production delivery system 10 according to the present embodiment. Here, 310 is an order approval unit that receives a sales order from a trading company, 350 is an order specification adding unit that supplies sales order information to the sales production delivery system 10, and 360 is inventory information that supplies inventory information to the sales production delivery system 10. The editing unit 370 is a production collection result collection unit that supplies production collection result information to the sales production delivery system 10. Further, the sales production delivery system 10 includes a production planning unit 510, an operation command unit 610, a delivery management unit 710, and a shipping unit 810.

  FIG. 2 is a detailed internal configuration diagram of the sales production delivery system 10 shown in FIG. In this figure, reference numeral 410 denotes a grouping processing unit which inputs the sales order information, take-up schedule information, inventory information, and production take-up record information already described with reference to FIG. 1 and will be described in detail later (see FIG. 5). Execute grouping processing. The grouping processing unit 410 includes an arithmetic processing unit (not shown) and various memories, and the arithmetic processing unit executes a processing operation according to a processing procedure stored in advance in a specific memory.

  Reference numeral 411 denotes a sales order database (hereinafter abbreviated as DB) storage unit that stores information as illustrated in FIG.

  Reference numeral 412 denotes a take-up schedule DB storage unit that stores information as exemplified in FIG.

  Reference numeral 413 denotes an inventory DB storage unit that stores information as illustrated in FIG.

  Reference numeral 414 denotes a production receipt record DB storage unit that stores information as illustrated in FIG.

  Reference numeral 426 denotes a manufacturing order DB storage unit that stores information as exemplified in FIG.

  Reference numeral 427 denotes a diagnostic information DB storage unit that stores information as exemplified in FIG.

  Reference numeral 428 denotes an inventory days setting reference storage unit, which stores a processing result by an inventory days setting processing unit 423 described in detail later.

  421 is a manufacturing order quantity determination processing unit, 422 is a reference date calculation processing unit, 423 is the above-mentioned inventory days setting processing unit, 424 is a delivery diagnosis processing unit, 425 is an inventory days diagnosis processing unit, 431 is a production lot aggregation processing unit, 432 Is a capability verification processing unit, 433 is a manufacturing start selection processing unit, and 440 is an alarm transmission processing unit. Each processing unit has an arithmetic processing unit and various memories not shown, and is stored in advance in a specific memory. Each arithmetic processing unit executes a processing operation according to the processing procedure. In addition, it is also possible to configure so that the processing in each processing unit described above and the grouping processing unit 410 described above is executed by a single central processing unit.

  Next, the operation of each processing unit shown in FIG. 2 will be described sequentially.

  FIG. 5 illustrates a grouping key for explaining the operation of the grouping processing unit 410. The grouping key is a word that represents the type of steel (sales / manufacturing) / transport route. In the grouping processing unit 410, [1] sales order information, [2] take-up schedule information, [3] inventory information, and [4] production take-up record information are grouped with a common mesh that represents the type and transport route of steel materials. The grouping key is defined and key information is added.

  Here, the above [1] sales order information is issued when sales order information is newly generated, and is stored in a master table (not shown). [2] Take-up schedule information is used to search the master table when creating the take-up schedule information, and is created with a mesh of key information. Then, key information is passed in the order of sales order information → manufacturing order information → in-stock information → [3] inventory information, and grouping is performed according to the keys. Further, [4] grouping is performed in accordance with the key information held in the production order information / in-stock information according to the production receipt result information.

  Next, a learning control operation by the inventory days setting processing unit 423 shown in FIG. 2 will be described with reference to FIGS. 6 and 7. Here, (A) of FIG. 6 illustrates storage information in the production takeover record DB storage unit 414 (see FIG. 2) as an input parameter used in the learning control.

  FIG. 6B is a diagram illustrating the definition of “inventory days” used in the present embodiment. In other words, the product inventory days are separated from the safety stock part for manufacturing variation and the safety stock part for take-up variation, and the safety stock part for manufacturing variation and the safety stock part for take-off variation are grouped by grouping key (steel code). Set. Also, when setting the reference date, the number of inventory days is given in order from the delivery date and each reference date is set.

  In the learning control method in the inventory days setting processing unit 423, every time a product is received and picked up, the production lead time fluctuation record (= delivery preparation completion reference date-the warehousing record date) / pickup fluctuation record (= delivery date of delivery) -Acquisition date) Accumulate values. Then, every time 10 new result values are generated, the manufacturing variation and the pick-up variation are calculated based on the 50 pieces of result information in the new order (the calculation method will be described later with reference to FIG. 7). The obtained calculated values are classified into large, medium and small, respectively (threshold is set based on the standard).

  Then, based on the large / medium / small determination of the manufacturing variation / take-off variation, the inventory days setting standard is corrected. Specifically, when it is large: Increase the inventory days at a constant pitch. Middle: Use the same value as before. When small: Reduce the number of days in stock at a fixed pitch.

  FIG. 7 is an explanatory diagram showing the concept of setting the number of days in stock according to the present embodiment in more detail. As for the change of the inventory days (that is, learning control), it is preferable to divide into two categories: (1) the delivery date to the delivery preparation completion reference date, and (2) the delivery preparation completion reference date to the warehousing reference date. .

(1) About the delivery date to the reference date for completion of delivery preparation:
When take-over variation <inventory days update judgment decrease side (take-off) → Set value + x days.

  When inventory days update judgment is reduced (take-off) ≤ take-up variation ≤ inventory days update judgment is increased (take-off) → Set value.

  When stocking variation> inventory days update judgment increase side (acquisition) → Set value-x days.

(2) About the delivery preparation completion reference date to the receipt reference date:
When manufacturing variation <inventory days update judgment reduction side (manufacturing) → Set value + y days.

  When the inventory days update judgment decrease side (manufacturing) ≤ manufacturing variation ≤ inventory days update judgment increase side (manufacturing) → "Set value".

  When manufacturing variation> inventory days update judgment increase side (manufacturing) → Set value-y days.

  Each parameter is uniformly set with a grouping key (steel code).

  FIG. 7 shows an image of setting the number of days of stock from the delivery date to the shipment order limit date obtained in this way.

  Next, a method for calculating the take-up variation and manufacturing variation used in the learning control will be described.

In this embodiment, every time 10 warehousing / acquisition results are generated, the latest 50 warehousing / acquisition results are calculated. At this point,
Dispersion of delivery = average of (delivery date-actual delivery) + standard deviation of (delivery date-actual delivery). However, the delay is not subject to calculation.

For manufacturing variations,
Production variation = average of (preparation date for completion of delivery preparation-actual record of receipt) + standard deviation of (reference date for completion of delivery preparation-actual record of receipt). However, the preceding is not subject to calculation.

  Next, referring again to FIG. 2, the storage process in the production takeover record DB storage unit 414 (referred to as step S <b> 1), the calculation process in the inventory days setting processing unit 423 (referred to as step S <b> 2), and the inventory days setting standard. A storage process (referred to as step S3) in the storage unit 428 will be described.

  In step S1, the production lead time fluctuation record (= delivery preparation completion reference date−receipt record date) / pickup fluctuation record (= delivery date of delivery−pickup date) is stored in the production takeover record DB storage unit 414 every time the product is received and picked up. Accumulate and store values.

  In step S2, the inventory days setting processing unit 423 calculates the manufacturing variation / take-off variation as described above based on the 50 latest results information every time 10 new actual values are generated. Then, the calculated values are classified into large, medium, and small, respectively (threshold value is set in advance based on a standard).

  In step S <b> 3, the inventory days setting reference is corrected based on the above-described large / medium / small determination of the manufacturing variation / take-off variation, and stored in the inventory days setting reference storage unit 428. That is, when the determination is large, the number of inventory days is increased at a constant pitch, when the determination is medium, the conventional value is used, and when the determination is small, the number of inventory days is decreased at a constant pitch.

  FIG. 8 is an operation explanatory diagram of the manufacturing order amount determination processing unit 421 shown in FIG. The horizontal axis of the table shown at the top of the figure represents the repeatability of take-up in terms of grouping key units. The vertical axis of the table represents the scale of receipt.

The production order quantity determination policy here is as follows.
1) If there is repeatability and the take-up scale is large (the monthly take-up amount is greater than or equal to the upper limit of the slab design), the policy is to “maximize unit weight achievement” (that is, to improve production efficiency).
2) If repeatability is present and the take-up scale is moderate (the monthly take-up amount is less than the slab design upper limit or more than the slab design lower limit), the policy is to “maximize product weight” (ie increase inventory) Pursue the next best efficiency in production and transportation while deterring).
3) If the repeatability is low or the take-up scale is small (the monthly take-up amount is less than the slab design lower limit), the policy is to “minimize surplus generation”.

  As for the unit weight achievement index, the slab unit weight and the product unit weight are not necessarily synchronized as illustrated in the lower part of FIG. 8, and which of the slab priority and the product priority is advantageous? Because it is case-by-case, we evaluate which one is advantageous for each steel group using the evaluation formula.

  FIG. 9 is a flowchart showing a processing procedure for determining the manufacturing order quantity.

  First, in step S10, according to the specifications of the standard, dimensions, and the passing process, the sales order specification adding unit 350 (see FIG. 1) selects the production order candidate for the case of the slab upper limit target case and the product single weight upper limit target case. calculate.

  In step S11, the calculated data is stored in the sales order DB storage unit 411 (see FIG. 2).

  In step S12, the data is extracted from the sales order DB storage unit 411.

  In parallel with the above steps S10 to S12, in step S13, take-up schedule data is read from the take-up schedule DB storage unit 412 (see FIG. 2).

  In step S14, the repeatability / take-up scale in units of grouping keys (steel material codes) is calculated based on the take-up schedule data from the take-up schedule DB storage unit 412.

  In step S15, a production order setting policy is determined based on the repeatability / take-over scale, and a production order amount is determined based on a unit weight achievement degree evaluation formula or the like.

  In step S16, the production order quantity is output from the production order quantity determination processing unit 421.

FIG. 10 is an explanatory diagram showing a concept for calculating a reference date in the reference date calculation processing unit 422 (see FIG. 2). In this figure, the period between steelmaking and delivery is classified into periods according to the respective characteristics. Based on this feature, the inventory days setting standard is classified into the following three groups.
(Group 1) Manufacturing variation: The required number of days is set for each passing process.
(Group 2) Variation in transportation: Variations in transportation are characterized by transportation flights and delivery locations.
(Group 3) Customer takeover variation: The change in takeover is characterized by the customer / delivery location.

  FIG. 11 is a flowchart showing a processing procedure in the reference date calculation processing unit 422 (see FIG. 2).

  In step S <b> 20, the sales order specification read from the sales order DB storage unit 411 is input via the manufacturing order amount determination processing unit 421.

  In step S <b> 21, an inventory days setting reference is input from the inventory days setting reference storage unit 428.

  In step S22, the inventory days are set by allocating the inventory days of each reference day from the inventory days setting reference based on the sales order specification.

  In step S 23, the inventory data read from the inventory DB storage unit 413 is input via the manufacturing order amount determination processing unit 421.

  In step S <b> 24, take-up schedule data read from the take-up schedule DB storage unit 412 is input via the manufacturing order amount determination processing unit 421.

  In step S25, a stockout forecast date is calculated from the inventory and the take-off schedule for each grouping key (steel material code), and this is set as the delivery date.

  In step S26, the number of inventory days is given in order from the delivery date and a reference date is set.

  In step S27, the calculated reference date is stored in the production order DB storage unit 426.

  The reference date stored in this way can be used not only for designating the production target period in the production lot aggregation processing unit 431 (see FIG. 2) but also for the delay advance evaluation in the delivery management unit 710 (FIG. 1).

  FIG. 12 is an explanatory diagram showing how production lots are organized in the production lot aggregation processing unit 431 shown in FIG. In the example shown in this figure, the processing conditions that are strongly regulated in each manufacturing process / transport route are processed together under the same processing conditions. Each input parameter and manufacturing order information corresponding to each input parameter are as follows.

Input parameter [Production order information]
Steel production [If the component system is rare, the lots are arranged according to the steel production pitch.
I do. For example, one steel grade that only has a chance once a month
Applicable up to the date of the date of the date of steel extraction. ]
Plating [For rare types of plating, match the plating pitch.
Lot summarization. For example, only once a month
The plating types are those up to the plating reference date one month ahead.
The ]
Transport [If the target amount is small by transport route,
Lot with a pitch that matches the transport lot determined by the city
Do. For example, a transportation route with only a monthly chance
Covers the date up to the base date for preparation for delivery one month ahead.
]

  FIG. 13 is an explanatory diagram showing a procedure of a manufacturing start instruction by the capability verification processing unit 432 and the manufacturing start selection processing unit 433 shown in FIG. In the present embodiment, making a steel request on the day or extracting a production order to be allocated to the material on the day is referred to as a production start instruction. The input parameters necessary for obtaining the above manufacturing start instruction are manufacturing order information and equipment operation schedule.

  In FIG. 13, when there is no lot summarization, a production start instruction is issued on the day within a range that satisfies the capacity frame of the planning target period, in accordance with the steel production reference date or the material allocation reference date of the production order. In the case of lot summarization, start of production on the same day within the range that meets the capacity frame of the target period for those that fall within the lot summarization period in accordance with the steel production base date of the production order or the material provision base date Give instructions.

  Note that the operation schedule instruction processing unit 434 (see FIG. 2) provisionally determines a production order to be planned on the day, and evaluates the load of each production process. The capacity of each manufacturing process is obtained from the operation schedule. Further, the capacity and load of each manufacturing process are compared, and a manufacturing order frame that satisfies the capacity frame is set. Thus, the manufacturing start instruction is given based on the manufacturing order frame within the range satisfying the capacity frame.

  FIG. 14 is an operation explanatory diagram of the inventory days diagnosis processing unit 425 shown in FIG. Input data necessary for performing the inventory days diagnosis is read from the inventory days setting reference storage unit 428. Then, for each grouping key (steel material code) unit, the correction value set by the inventory days setting processing unit 423 is searched, and the correction value corrected to the increase side is extracted. As the output data of the inventory days diagnosis processing unit 425, the inventory days correction value is written in the diagnosis information DB storage unit 427.

  As a result, the problem can be extracted by searching the diagnostic information DB storage unit 427 in order of increasing correction value and increasing size.

  15 and 16 are explanatory diagrams showing the concept and operation of delivery diagnosis in the delivery diagnosis processing unit 424 (see FIG. 2). Input data necessary for delivery diagnosis in the present embodiment is read from the production order DB storage unit 426. Then, for each grouping key (steel code), calculate the product inventory, product inventory + work-in-process inventory, production order unshipped remaining total amount, and whether each is within the appropriate inventory days management range compared to the take-off schedule Determine. The determination result (output data) is written in the diagnostic information DB storage unit 427.

  Here, FIG. 15 shows a diagnosis method when the product inventory is insufficient. For example, a diagnosis result as shown in FIG. FIG. 16 shows a diagnosis method when the product + in-process inventory is insufficient or the unshipped balance is insufficient. For example, a diagnosis result as shown in FIG. 17B is obtained. Then, problems can be extracted based on these diagnosis results.

  FIG. 18 is an explanatory diagram of the operation of the alarm transmission processing unit 440 shown in FIG.

  Input data necessary for processing for generating an alarm is read from the diagnostic information DB storage unit 427. Then, as a result of the determination of the appropriate inventory days for each grouping key (steel code), if the product inventory is less than 2 weeks of the scheduled take-off amount, alarm information is transmitted to the sales / trading company.

  In “Case 1” shown in FIG. 18, the take-over amount has exceeded the initial plan, and even if the apparent product stock is small, the total of the take-up amount and the stock amount can cover up to two weeks ahead of the plan. If there is no alarm. On the other hand, if it cannot be covered, an alarm is transmitted.

  In “Case 2” shown in FIG. 18, conversely, if the take-off amount is short, even if there is a large apparent product stock, the sum of the take-up amount and the stock amount cannot be covered up to two weeks ahead of schedule. If so, send an alarm. On the other hand, if it is covered, there is no alarm.

  Next, the relationship between delivery diagnosis and inventory days diagnosis will be described.

  The delivery diagnosis is for preventing the occurrence of a delivery trouble by determining whether or not the inventory is within an appropriate range by comparing the inventory with the scheduled delivery. On the other hand, in the inventory days diagnosis, a product having a particularly long lead time or a product having a large variation is extracted so that a product can be produced with an appropriate lead time. In other words, it is intended to clarify the problem of manufacturing and the variation of customer take-up.

  Further, an alarm is generated in the delivery diagnosis every day at the time when the taking-out schedule is compared with the inventory. On the other hand, the occurrence of an alarm in the inventory days diagnosis is made at the time when the inventory days are set every time when, for example, ten collection keys / steering records are counted for each grouping key (steel code).

(Summary)
In the above-described embodiment, as for the four problems (a) to (d) described in the column “Problems to be solved by the invention”, the following special solutions are provided.

  (A) About shortening of paper lead time.

Information on the stock of steel sheets and strip products collected through the inter-company network and updated to the latest state every day and information on customer takeover schedules are directly connected to the factory, and production orders are extracted at the factory.
Calculate the out-of-stock occurrence forecast date from the in-process inventory / product inventory and the customer's take-over schedule for each production order, and use the forecast date of out-of-stock occurrence as a starting point, based on the appropriate inventory days setting criteria, Calculate the base date for completion, the base date for processing each manufacturing process, and the base date for starting production
By making it possible to extract a production order with a production start instruction reference date that matches the production start instruction period of the day, and to instruct the start of production,
Using the latest information every day, it is possible to make a production start decision while matching the order volume and production capacity, so there is no need to pool orders for about 10 days at the head office, reducing paper lead time. can do.

  (B) Consistency between production lot and order quantity.

Based on the taking-out scale and repeatability calculated from the taking-out schedule / actual results, determination of the production order quantity per production that minimizes manufacturing / distribution costs,
Production lot aggregation that aggregates production orders within the range that satisfies the production completion reference date according to the lot of the production process, and issues a production start instruction,
Set the tolerance range for the delivery preparation completion date,
By making it possible to optimize the product transportation lot in relation to the delivery preparation completion reference date by consolidating and transporting products with the same transportation route to distribution centers such as service centers within the allowable range,
Since it is possible to match the production lot with the order quantity, it is possible to reduce the occurrence of surplus and waiting for a production chance.

  (C) About the setting of the appropriate inventory days.

Stores the results of lead time fluctuations from the start of manufacturing to the completion of manufacturing, and the difference between the delivery deadline date and the actual delivery date for each similar specification part / delivery route unit,
Using actual results information, statistically evaluate the difference between the target and actual results for each type of specification part / delivery route,
i) Update and set the appropriate inventory days by learning control method based on the actual results:
ii) Diagnose the content of the standard for setting the appropriate inventory days, and send an alarm for those that have a particularly large gap between the target and actual performance:
By
The inventory days can be kept in a good state by encouraging the investigation improvement for the abnormal one without increasing the difference between the inventory days setting value and the actual condition.

  (D) Dealing with fluctuations in customer usage fluctuations, and overlapping management between sales / trading companies and factories.

By extracting production orders at the factory, by capturing changes that hinder delivery, such as appropriate inventory cracking, monthly steps to be picked up, divergence between pick-up schedules and actual results, and sending alarms to relevant departments,
The sales / trading company can use the delivery diagnosis information sent from the factory as long as it promptly informs the factory of changes in the customer's usage schedule, and can eliminate duplication of product progress management operations. . In other words, it is possible to eliminate duplicate work by enhancing the delivery diagnosis function on the factory side.

2 Customer 4 Trading company 6 Factory 310 having sales production delivery system 10 according to the present embodiment Order acceptance approval unit 350 Order specification addition unit 360 Inventory information editing unit 370 Production receipt result collection unit 410 Grouping processing unit 411 Sales order DB (database) Storage unit 412 Take-off schedule DB storage unit 413 Inventory DB storage unit 414 Production take-over record DB storage unit 426 Manufacturing order DB storage unit 427 Diagnostic information DB storage unit 428 Inventory days setting reference storage unit 421 Manufacturing order amount determination processing unit 422 Reference date calculation Processing unit 423 Inventory days setting processing unit 424 Delivery diagnosis processing unit 425 Inventory days diagnosis processing unit 431 Manufacturing lot aggregation processing unit 432 Capability verification processing unit 433 Manufacturing start selection processing unit 440 Alarm transmission processing unit

Claims (7)

Information on customer takeover schedules related to steel sheet steel strip products, customer takeover schedule information storage means for storing information while updating to the latest state,
Sales order storage means for storing information on ordering of steel sheet steel strip products from customers and product specifications;
Actual information storage means for storing the results of fluctuations in lead time from the start of production to the completion of production, and the results of deviations between the delivery deadline date and the actual delivery date for each similar specification part / delivery route unit,
The actual information stored in the actual information storage means is used to statistically evaluate the difference between the target and actual results for each of the same specification parts and delivery routes, and based on the actual results, the appropriate inventory days by the learning control method Inventory days setting means for sequentially updating setting criteria;
Diagnosing the content of the appropriate inventory days setting criteria updated and set by the inventory days setting means, and setting inventory days diagnosis means for instructing the alarm transmission for the difference between the target and the actual result exceeding a predetermined value;
One-time production / distribution cost is minimized based on the take-up schedule stored in the customer take-up schedule information storage means and the take-up scale calculated based on the take-out record and / or the presence or absence of repeatability. Production order quantity determining means for determining the production order quantity per unit,
Calculate out-of-stock occurrence forecast date from work-in-progress inventory, product inventory and customer take-off schedule for each production order, and based on the appropriate inventory days setting criteria updated by the inventory days setting means from the out-of-stock occurrence forecast date A reference date calculating means for calculating a reference date for completion of delivery preparation, a reference date for completion of manufacturing, a reference date for each manufacturing process processing, a reference date for instructing to start manufacturing, or several reference dates;
Output information from the reference date calculation means, manufacturing order storage means for storing information relating to production management including at least one of product manufacturing specifications, delivery deadline date, and manufacturing completion deadline date;
A production lot aggregation unit that inputs information from the production order storage unit and aggregates production orders in a range that satisfies the production completion reference date according to a lot of a production process;
A production start instruction means for extracting a production order having the production start instruction reference date suitable for the production start instruction period of the current day based on the output of the production lot aggregation means, and instructing the start of production. Sales and production delivery system for steel strip products. In the sales production delivery system according to claim 1,
Steel plate characterized by having alarm sending means to catch the change that interferes with delivery, including proper inventory cracking, monthly level difference to be picked up, difference between picking up plan and actual record Sales production delivery system for steel strip products. In the sales production delivery system according to claim 1,
Sales orders, manufacturing orders, work in progress, and product actual products are grouped by product specifications, manufacturing specifications, and transportation routes, and the sales order storage means, the customer take-up schedule information storage means, the actual information storage means, and the inventory database A sales production delivery system for steel sheet steel strip products comprising grouping processing means for outputting corresponding data to the storage means. In the sales production delivery system according to claim 1,
Set the tolerance range for the delivery preparation completion reference date, and aggregate and transport products with the same transportation route to the distribution base within the tolerance range to optimize the product transportation lot in relation to the delivery preparation completion date. , Sales and delivery system for steel strip products, characterized by increasing the loading rate of transport per time, that is, product volume ÷ maximum loading capacity. In the sales production delivery system according to claim 4,
When optimizing the product transportation lot, set the product unit weight tolerance range taking into account customer acceptance restrictions when adding order specifications, and use the unit weight achievement evaluation formula in the production order quantity determination means to achieve product unit weight. Sales, production and delivery system for steel strip products, characterized in that the degree is controlled so as to maintain a high level within an allowable range. In the sales production delivery system according to claim 4,
In optimizing the product transportation lot, the production lot aggregation means matches the transportation lot by aggregating the products of rare transportation routes for each transportation lot unit based on the delivery preparation completion reference date and instructing the production start. Sales, production and delivery system for steel strip products, characterized by guaranteeing product assortment. A customer take-up schedule information storage step for storing information on a customer's take-up schedule related to steel sheet steel strip products while updating to the latest state;
A sales order storage step for storing information on ordering of steel sheet steel strip products from customers and product specifications;
A track record information storage step that stores the track record of lead time variation from the start of manufacturing to the completion of manufacturing and the track record of the difference between the delivery deadline date and the actual delivery date for each of the same specification part / delivery route unit,
Using the performance information stored in the performance information storage step, statistically evaluate the difference between the target and the performance for each of the same specification parts / delivery routes, and set the appropriate inventory days using the learning control method based on the performance Inventory days setting step to update the criteria sequentially,
Diagnosing the contents of the appropriate inventory days setting criteria updated and set in the inventory days setting step, setting inventory days diagnosis step for instructing the alarm transmission for the difference between the target and the actual value exceeds a predetermined value;
Based on the take-up schedule stored in the consumer take-up schedule information storage step and the take-out record, and / or the presence / absence of repeatability, the production / distribution cost is minimized. A production order quantity determination step for determining a production order quantity for
Calculate out-of-stock occurrence forecast date from work-in-progress inventory, product inventory and customer take-off schedule for each production order, and based on the appropriate inventory days setting criteria updated in the inventory days setting step from the out-of-stock occurrence forecast date A reference date calculation step for calculating a reference date for completion of delivery preparation, a reference date for completion of manufacturing, a reference date for processing each manufacturing process, a reference date for instructing to start production, or several reference dates;
A manufacturing order storage step of inputting calculation information in the reference date calculation step and storing information relating to production management including at least one of a product manufacturing specification, a delivery deadline date, and a manufacturing completion deadline date;
A production lot aggregation step of reading out the storage information by the production order storage step and aggregating the production orders in a range satisfying the production completion reference date according to the lot of the production process;
A production start instruction step for extracting a production order having the production start instruction reference date that conforms to the production start instruction period of the current day based on the output of the production lot aggregation step, and instructing the start of production. Sales, production and delivery method for steel strip products.

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