JP5168481B2 - Production schedule planning system, production schedule planning method, and production schedule planning program - Google Patents

Description

  The present invention relates to a production schedule planning system, a production schedule planning method, and a production schedule planning program for planning (calculating) a product production schedule.

  Companies manage inventory of products they sell. When the inventory is large, the burden on costs such as storage and defective inventory becomes large. Conversely, when the inventory is low, storage costs and the like can be reduced, but there is a possibility that the opportunity to sell the product will be missed. In view of this, companies have devised measures to maintain an appropriate inventory by managing the inventory of products.

In order to maintain an appropriate inventory, a technique for determining a production model and a production number for each production line based on a replenishment amount for each model has been studied (for example, see Patent Document 1). In this document, the replenishment amount data for each model, the production model data for the production model, the production line data for the production line, and the constraint condition data in determining the number of production are taken in, and based on these data, Determine the production volume. When the production model and the number of production are determined for each production line, the calculation result is displayed and output on the terminal of the production management server. Then, when the determined production quantity (production schedule) for each day and the modification of the constraint condition are performed using the terminal, the production quantity is recalculated using the changed constraint condition. In this case, as the constraint condition data for determining the number of production units, the manpower fluctuation data for each production line set based on the constraint on overtime hours is used.
JP 2004-287623 A (FIG. 2)

  In the technique described in the above-mentioned document, the production schedule can be determined again from the production system such as overtime or holiday work. However, adjusting the appropriate production system in consideration of the constraint conditions according to the calculated number of production takes time and effort, and has been a heavy burden.

  The present invention has been made in view of the above-described problems, and provides a production schedule planning system, a production schedule planning method, and a production schedule planning program for efficiently planning a production schedule according to a production system.

In order to solve the above-described problems, the invention described in claim 1 includes an inventory record storage unit that records the actual number of inventory records, and an inventory target range that is calculated from a sales plan and is corrected based on the inventory records. Control means connected to the inventory target value storage means to be recorded, system identifier for specifying the production system, normal production number produced by normal working hours of this production system, and overtime production number produced by overtime Production system condition storage means for storing the system maintenance days in association with each other, overtime limit storage means for storing overtime restriction conditions regarding the upper limit value of overtime, production schedule planning date, and production schedule system identifier a production schedule planning system and a production schedule storage means for storing in association with overtime flag, the control means, wherein And inventory target value acquiring means for acquiring inventory target range from refrigerator target value storage means, obtains the previous production schedule from the production schedule storage unit, identifies a system identifier contained in the production schedule, systems of these systems identifiers The maintenance days, normal production number and overtime production number are obtained from the production system condition storage means, and the overtime number in the previous production schedule is subtracted from the overtime upper limit value stored in the overtime restriction storage means. The number of overtime that can be increased is calculated, and the overtime students
Calculate the variable number by multiplying the number of production, and estimate the number of sales from the total number of goods received in the production system of the previous production schedule and the total number of overtime production corresponding to the overtime flag in this schedule The amount of fluctuation from the previous production schedule is calculated by reducing the planned inventory quantity that has been reduced from the actual number of inventory on the day included in the previous production schedule, and the fluctuation quantity exceeds the variable quantity. If not, the production system in the previous production schedule is determined as the production system of the current production schedule, and if the fluctuation amount exceeds the variable number, the system maintenance days are satisfied. , a production system determining means for changing the production system, said to be the inventory target range, the limits following overtime of the overtime, determined the production system Overtime determination means for allocating overtime and determining overtime; and plan recording means for recording the determined production system and production schedule including the overtime in the production schedule storage means. The gist.

The invention described in claim 2 further comprises loss cost calculation parameter storage means for storing a parameter in which a parameter for calculating loss cost regarding the production system and overtime is recorded in the production schedule planning system according to claim 1. The control means stores a loss cost calculation formula for calculating a loss cost of a production schedule and data relating to an evaluation reference value, and the control means stores parameters related to the determined production system and overtime in the loss cost calculation parameter storage. The loss cost is calculated by substituting into the loss cost calculation formula to calculate the loss cost, comparing the loss cost with the evaluation reference value, and performing a loss cost evaluation, and the loss cost evaluation by the loss cost evaluation means is performed. When the evaluation standard value is exceeded When the overtime determination means re-determines the overtime and the loss cost evaluation by the loss cost evaluation means does not exceed the evaluation reference value, the plan recording means stores the production schedule in the production schedule storage. The gist is to record in the means.

The invention according to claim 3 is connected to the inventory result storage means for recording the actual number of inventory results and the inventory target value storage means for recording the inventory target range calculated from the sales plan and corrected based on the inventory results. The control means, the system identifier that identifies the production system, the normal production number produced by the normal working hours of this production system, the overtime production number produced by overtime, and the system maintenance days The production system condition storage means stored in memory, the overtime limit storage means for storing the overtime limit condition related to the upper limit of overtime, the production schedule planning date, the production schedule system identifier, and the overtime flag are stored in association with each other. a the production schedule storage means and the production schedule planning method using a system wherein the control means, the inventory target value storing hand And inventory target value acquisition step for acquiring inventory target range, and acquires the previous production schedule from the production schedule storage unit, identifies a system identifier contained in the production schedule, system maintenance days these systems identifiers, usually produced the number and ultra <br/> number over work production obtained from the production system condition storage means, from the upper limit value of the stored overtime in the overtime limit storage means, subtracting the number of overtime in the previous production schedule The number of overtime that can be increased is calculated, the number of overtime is multiplied by the number of overtime production to calculate the variable number, the normal production number of the production system of the previous production schedule, Based on the total number of goods received with the number of overtime production corresponding to the overtime flag, the planned inventory quantity with the sales forecast number reduced is calculated as the previous production schedule. The amount of fluctuation from the previous production schedule is calculated by decreasing from the actual number of stocks included in the day, and if the fluctuation amount does not exceed the variable number, the production in the previous production schedule the system determines a production system of this production schedule, if the amount of the variation exceeds the number of available said variations, so as to satisfy the system maintenance days, the production system determining step of changing the production system, the so that inventory target range, the limits following overtime of the overtime, assigning the normal production quantity of the determined production system, and overtime determination step of determining overtime, determined production system and The gist is to execute a plan recording step of recording the production schedule including the overtime in the production schedule storage means.

The invention according to claim 4 is connected to the inventory result storage means for recording the actual number of inventory results and the inventory target value storage means for recording the inventory target range calculated from the sales plan and corrected based on the inventory results. The control means, the system identifier that identifies the production system, the normal production number produced by the normal working hours of this production system, the overtime production number produced by overtime, and the system maintenance days The production system condition storage means stored in memory, the overtime limit storage means for storing the overtime limit condition related to the upper limit of overtime, the production schedule planning date, the production schedule system identifier, and the overtime flag are stored in association with each other. a production schedule planning program in a system and a production schedule storage means, and said control means, said inventory target value Stock target value acquiring means for acquiring inventory target range憶means acquires the previous production schedule from the production schedule storage unit, identifies a system identifier contained in the production schedule, system maintenance days these systems identifiers, usually The number of production and the number of overtime production are acquired from the production system condition storage means, and the number of overtime in the previous production schedule is subtracted from the upper limit value of overtime stored in the overtime limit storage means, and increased. Calculate the number of overtime that is possible, multiply the number of overtime by the number of overtime production, and calculate the number of variable, and use the normal production number of the production system of the previous production schedule and the overtime flag in this schedule. From the total number of goods received with the corresponding number of overtime production, the planned inventory quantity with the forecasted sales number reduced is calculated as the previous production schedule. The amount of fluctuation from the previous production schedule is calculated by decreasing from the actual number of stocks included in the day, and if the fluctuation amount does not exceed the variable number, the production in the previous production schedule The system is determined as the production system of the current production schedule, and when the fluctuation amount exceeds the variable number, the production system determining means for changing to the production system so as to satisfy the system maintenance days , An overtime determination means for determining overtime by allocating overtime below the overtime limit to the normal production number of the determined production system so as to be within the inventory target range, and the determined production system and The gist of the invention is to function as a plan recording means for recording a production schedule including overtime in the production schedule storage means.

(Function)
According to the present invention, the control means acquires the inventory target range that is calculated from the sales plan and is corrected based on the actual inventory. The control means obtains the previous production schedule from the production schedule storage means, obtains the normal production number of the system identifier included in this production schedule and the overtime production number in the overtime included in this production schedule. The production system is determined so that the total number of production and overtime production falls within the inventory target range. The control means determines overtime by assigning overtime below the overtime limit to the number of normal productions of the determined production system so that the inventory target range is reached. The control means records the production schedule including the determined production system and overtime in the production schedule storage means. For this reason, the control means determines the current production system using the production schedule created last time, and automatically determines the overtime schedule that satisfies the overtime restriction condition in this production system. Therefore, a production schedule can be planned efficiently.

  According to the present invention, the control means calculates the number of overtime that can be increased by subtracting the overtime of the production system of the previously calculated production schedule from the upper limit value of overtime stored in the overtime limit storage means. The number of overtime production is multiplied by the number of overtime work to calculate the number of variable, and the inventory results for the day included in the previously calculated production schedule are obtained from the inventory results storage means, and the same period as this inventory results number When the fluctuation difference with the sales plan is calculated and the fluctuation difference is smaller than the variable number, the production system included in the previously calculated production schedule is used as the production system of the production schedule calculated this time. For this reason, when the difference between the previous production schedule and the actual inventory is within the range of the variable number, the control means diverts the production system of the previous production schedule as the current production system, so that more efficient production is possible. You can make a schedule.

  According to the present invention, the control means calculates the loss cost by substituting the parameters related to the determined production system and overtime into the loss cost calculation formula, compares the loss cost with the evaluation reference value, and performs the loss cost evaluation. Do. When the loss cost evaluation by the loss cost evaluation means exceeds the evaluation reference value, the control means re-determines overtime, and when the loss cost evaluation does not exceed the evaluation reference value, the production schedule is stored in the production schedule storage means. To record. For this reason, a production schedule with a low loss cost can be efficiently performed.

  According to the present invention, a production schedule can be planned efficiently.

Hereinafter, an embodiment embodying the present invention will be described with reference to FIGS. In the present embodiment, for example, a production schedule planning system for calculating a production schedule for a product such as a multi function printer (MFP) will be described. This production schedule planning system executes a production schedule planning process in consideration of the production system using the inventory target value calculated from the sales plan and the sales results.

  As shown in FIG. 1, the production schedule planning system 20 is connected to a production and sales monitoring system 10 for calculating a target stock value. This production and sales monitoring system 10 is connected to a sales department system (not shown). The production and sales monitoring system 10 includes a parameter storage unit and a sales performance data storage unit (not shown). Further, the production and sales monitoring system 10 includes a sales plan data storage unit 11 as a sales plan storage unit and an inventory target data storage unit 12 as an inventory target value storage unit.

In the sales record data storage unit, sales record data relating to the sales record number associated with the sales record date is recorded. This sales performance data is recorded when data related to sales performance is acquired from the sales department system. The sales performance data includes data related to the sales performance date and the number of sales performance.
In the sales record date data area and the sales record number data area, data related to the actual sales date and the number of sales are recorded.

As shown in FIG. 2A, the sales plan data storage unit 11 stores sales plan data 110 related to the planned sales volume associated with the planned sales date. The sales plan data 110 is recorded when it is calculated using parameters and sales performance data periodically stored in the parameter storage unit. The sales plan data 110 includes data related to the sales plan date and the sales forecast number.
In the sales plan date data area and the sales forecast number data area, data related to the forecast date on which the sales forecast is made and the forecasted sales quantity are recorded.

  The inventory target data storage unit 12 stores inventory target data 120 as shown in FIG. The inventory target data 120 is recorded when the production / sales monitoring system 10 calculates the inventory target data 120 using the sales plan data 110 and the sales performance data. In addition, when the already recorded inventory target data 120 is newly calculated, the new inventory target data 120 is recorded and updated. The inventory target data 120 includes data relating to an inventory target date, an inventory target value, an inventory upper limit value, an inventory lower limit value, and a current inventory schedule.

Data related to the date of the inventory target is recorded in the inventory target date data area.
In the stock target value data area, data related to the stock target value (target value) on this stock target date is recorded.

In the stock upper limit data area and the stock lower limit data area, data relating to the upper limit value and the lower limit value of the stock quantity on the stock target date is recorded.
In the current inventory schedule data area, data relating to the number of inventory (current inventory schedule) predicted from the current production schedule and sales plan is recorded. The current inventory schedule is calculated by adding the number of receipts produced on the current schedule according to the production schedule to the current inventory schedule of the previous day and subtracting the sales forecast number for the current sales plan by the production and sales monitoring system 10. Is done.

On the other hand, the production schedule planning system 20 shown in FIG. 1 acquires the inventory target data 120, plans (calculates) a production schedule considering the production system, and transmits the production schedule to the production management system 30 to give a production instruction. . The production schedule planning system 20 is connected to an administrator terminal 26 used by an administrator who manages the production schedule. The administrator terminal 26 includes display means such as a display and input means including a keyboard and a pointing device.

  The production schedule planning system 20 includes a control unit 21, a condition data storage unit 22, an inventory performance data storage unit 24, and a production plan data storage unit 25. The condition data storage unit 22 functions as a production system condition storage unit, a system application condition storage unit, an overtime restriction storage unit, and a loss cost calculation parameter storage unit. The inventory record data storage unit 24 functions as an inventory record storage unit, and the production plan data storage unit 25 functions as a production schedule storage unit.

  The control unit 21 includes a CPU, memory (RAM, ROM, etc.) and the like (not shown). And this control part 21 performs the process (Process including an inventory target value acquisition stage, a production system determination stage, an overtime determination stage, a loss cost evaluation stage, a production schedule recording stage, etc.) mentioned later. By executing the production schedule planning program for this purpose, the control unit 21 causes the simulation selection means 212, the remaining holiday adjustment simulation execution means 213, the system determination simulation execution means 214, the specification change simulation execution means 215, and the loss cost evaluation processing means 216. And output processing means 217. Here, the simulation selection means 212 functions as an inventory target value acquisition means. The remaining holiday adjustment simulation execution means 213 functions as overtime determination means, and the system determination simulation execution means 214 functions as production system determination means. The loss cost evaluation processing unit 216 functions as a loss cost evaluation unit, and the output processing unit 217 functions as a plan recording unit.

  The simulation selecting means 212 acquires inventory target data 120 at a predetermined start time, determines the variable number using the inventory target data 120 and production plan data 250 described later, and executes the simulation. Determine the type. For this reason, the simulation selection unit 212 of the embodiment stores a startup time determined for each week and a variable number calculation program for calculating the variable number. In the present embodiment, the variable number that can be increased is calculated by calculating the number of overtime days and holiday work days for each predetermined period (for example, one week), and the number of overtime production or holiday production is calculated for these days. Calculated by multiplying and adding. Note that the holiday production volume is the same as the normal production volume. In addition, the variable number that can be subtracted is added by multiplying the number of overtime days and the number of days off work included in the production plan data 250 for each predetermined period by multiplying the number of overtime production and the number of days off work, respectively. Is calculated by Further, the simulation selection means 212 stores data relating to the upper limit value and the lower limit value of the target range. If there is no determined variable number within the target range, the simulation selecting unit 212 changes the simulation to be executed.

The remaining time adjustment simulation execution means 213 executes a simulation for adjusting overtime and holiday work (remaining time adjustment simulation).
The system determination simulation execution means 214 executes a simulation (system change simulation) for determining a production system for each production day. In addition, the control part 21 of this embodiment performs the above-mentioned rest adjustment simulation, when a production system is determined by this system change simulation.

The specification change simulation execution means 215 executes a simulation (non-spec simulation) in which the constraint conditions in the above-described system change simulation are changed. For this reason, the specification change simulation execution means 215 stores data relating to the change order and the maximum allowable overtime days as the changeable number. This change order includes an item for specifying a specification to be changed and an order for changing the specification. In the present embodiment, the change is made in the order of “allowable overtime days” and “change width” in the change specification. In this case, in the order of the overtime allowable days changing process, the production system changing process, and the remaining days adjustment process, the simulation is executed by repeatedly changing the overtime permitted days and the fluctuation range of the variable specifications.

  The loss cost evaluation processing means 216 executes a calculation process of evaluation (loss cost evaluation) such as a production schedule from the cost aspect. In the present embodiment, this loss cost evaluation is performed for determining and determining the production schedule calculated by the simulation by the remaining holiday adjustment simulation execution means 213 or the specification change simulation execution means 215. The loss cost evaluation processing means 216 stores data related to a loss cost calculation formula and an evaluation reference value. Here, the loss cost calculation formula is a formula for calculating the loss cost based on the production schedule using the data of the loss cost calculation master described later and the parameter data of the calculated production schedule. When the calculated loss cost exceeds the evaluation reference value, the loss cost evaluation processing unit 216 causes the remaining holiday adjustment simulation execution unit 213 or the specification change simulation execution unit 215 to execute the simulation again.

  The output processing unit 217 executes output processing for the determined production schedule. In the present embodiment, the output processing unit 217 creates review sheet screen data and displays the review sheet screen on the display of the administrator terminal 26. Further, the output processing means 217 stores data in the production plan data storage unit 25 when the manager terminal 26 detects selection of the production schedule determination button included in the review sheet screen. Then, the output processing means 217 supplies the data stored in the production plan data storage unit 25 to the production management system 30.

  On the other hand, as shown in FIG. 2C, the condition data storage unit 22 records condition data used for planning a production schedule. This condition data is recorded when the production terminal planning conditions are set in the manager terminal 26. This condition data includes plan period data 221, holiday calendar data 222, variable specification data 223, and loss cost calculation master data 224.

Data related to the period of the production schedule to be calculated is recorded in the planned period data area. In this embodiment, 90 days is used as the period of this production schedule.
In the holiday calendar data area, data relating to days of the week and holidays is recorded for each year, month, and day.

  The variation specification data 223 includes production system data 231, variation width data 232, overtime allowance condition data 233, and leave allowance condition data 234. In the present embodiment, the production system data 231, the overtime allowance condition data 233, and the leave allowance condition data 234 constitute an overtime restriction condition regarding the upper limit value of overtime.

The production system data 231 includes data relating to a production system identifier, normal production quantity, overtime production quantity, maximum overtime count, and production maintenance days.
In the production system identifier data area, data relating to an identifier (production system identifier) for specifying each production system is recorded.

  In the normal production quantity data area, data relating to the quantity produced within the normal working hours of one day in this production system is recorded. In the present embodiment, for each production system identifier, the numbers “40”, “80”, “120”, “160”, “200”, “240”, and “280” are used as normal production numbers. .

In the overtime production unit data area, data relating to the number of units per day (overtime production units) increased by overtime in this production system is recorded.
In the maximum overtime data area, data relating to the maximum number of overtime that can be set in the production system is recorded.

In the system maintenance days data area, data on the minimum number of days to maintain each system after changing to this production system is recorded.
In the fluctuation range data area, fluctuation range data 232 that is allowable when changing each production system is recorded. In the present embodiment, “one step” is recorded as the fluctuation range. That is, when “one stage” is recorded, it means a production system of the normal production number adjacent to the normal production number of this production system. For example, in the case of a production system in which the normal production number is “160”, the production system of “200” or “120” is one stage.

  The overtime allowance condition data 233 includes data related to the overtime allowance days and the overtime allowance setting period. In the overtime allowable days data area and the overtime allowable setting period data area, the number of days that allow overtime (allowable overtime days) and data related to the setting period of the days are recorded. For example, when 10 overtime per month can be permitted, “10” is set in the overtime allowable days data area, and “1 month” is set in the overtime allowable setting period data area.

  The leave allowance condition data 234 includes data on the number of days allowed for holiday attendance and the leave allowance setting period. The number of days allowed for holiday work (allowable days for holiday work) and data relating to the setting organization for the number of days are recorded in the leave allowable days data area and the leave allowance setting period data area. For example, when a holiday attendance can be performed once a week, “1” is set in the leave permitted days data area, and “1 week” is set in the leave allowance setting period data area. .

  In the loss cost calculation master data area, loss cost calculation master data 224 used for calculating the loss cost is recorded. In this embodiment, the loss cost calculation master data includes working condition master data, system preparation condition master data, and inventory loss cost calculation master data.

The working condition master data includes data on normal working hours, overtime hours, employment days, wages and benefits.
In the normal work time data area and the overtime data area, data related to normal work hours and allowable overtime hours in a one-day employment contract is recorded. In this embodiment, 2 hours are used as overtime hours per day.

In the employment day data area, data relating to the number of employment days according to the employment contract of each employer is recorded.
In the wage data area, data on wages (amounts) of each employer during normal work is recorded.

  In the allowance data area, data on overtime allowance, holiday attendance allowance, and holiday overtime allowance are recorded. The amount of these allowances is calculated from a premium rate determined in advance according to the type of allowance and wage data.

  In the system preparation condition master data area, a system change condition for changing the production system is recorded. In this system preparation condition, data on the number of personnel to be increased (or decreased) when the production system is changed by one stage and the number of system preparation days until the production system is shifted are recorded.

In the inventory loss cost calculation master data, data related to the running cost required to store the product as inventory is recorded. In this lining cost, data relating to storage costs, the amount borrowed for the purchase of raw materials for goods, and the interest rate on the amount are recorded.

  On the other hand, the stock record data 240 is recorded in the stock record data storage unit 24 as shown in FIG. This stock record data 240 is recorded every day when the number of warehousing results and the number of warehousing results are determined. The inventory record data 240 includes data relating to the inventory record date, the number of warehousing records, the number of warehousing records and the number of inventory records.

In the actual inventory date data area, data related to the date on which each actual inventory is recorded is recorded.
In the warehousing record number data area and the warehousing record number data area, data relating to the number of products actually produced and received on this inventory record date and the number of products actually issued are recorded.

  In the actual inventory number data area, data relating to the inventory amount on the actual inventory date is recorded. The actual number of inventory is the number obtained by adding the actual number of warehousing on the day of actual inventory and subtracting the actual number of storage on the same day from the actual number of inventory on the day before the actual inventory date.

  On the other hand, the production plan data storage unit 25 records production plan data 250 as shown in FIG. The production plan data 250 is recorded when the production schedule planning system 20 performs a production schedule planning process. The production plan data 250 includes data relating to a calculation date, a point date, a production system identifier, an overtime flag and an adjustment scheduled stock.

In the calculation date data area, data related to the date on which the production schedule is drafted (generated) is recorded.
In the point date data area, data on each date of production determined by the production schedule is recorded.

In the production system identifier data area, data relating to an identifier (production system identifier) for specifying the production system on each point date is recorded.
In the overtime flag data area, data on overtime on each point date is recorded. In this embodiment, a flag of “0” indicating that there is no overtime on this point, a flag of “1” indicating that there is overtime, a flag of “2” indicating that there is a holiday attendance, or a holiday attendance In addition, a flag “2” indicating that there is overtime is recorded.

  In the adjustment planned inventory data area, data related to a planned inventory amount (adjustment planned inventory) generated from the number of units produced by the production system adjusted on each point date is recorded. This planned adjustment inventory data is obtained by subtracting the number of sales forecasts for the day in the sales plan data 110 from the number of goods received that is the sum of the normal production number of the production system and the number produced corresponding to the overtime flag for the day. Calculated.

  Next, the process procedure of the production schedule planning process using the system described above will be described with reference to FIG. In the present embodiment, the production schedule planning system 20 performs a production schedule planning process at the beginning of the week. For this reason, the production and sales monitoring system 10 updates the inventory target data 120 used for this before performing the production schedule planning process. Specifically, the production and sales monitoring system 10 uses the built-in calendar function to calculate the inventory target data 120 and store it in the inventory target data storage unit 12 when the current day falls on a weekend.

(Production schedule planning process)
The control unit 21 of the production schedule planning system 20 executes production schedule planning processing every week at the beginning of the week. Specifically, when the date of the internal clock is changed, the control unit 21 determines whether or not the current date corresponds to the beginning of the week using a calendar function. When the current date corresponds to the beginning of the week, the control unit 21 executes a production schedule planning process.

  In the production schedule planning process, the control unit 21 executes a stock date / variable number determination process on the point date (step S1-1). Specifically, first, the simulation selection unit 212 of the control unit 21 acquires the plan period data 221 of the condition data storage unit 22 and specifies the date of the plan period end date from the current date. Further, the simulation selecting unit 212 acquires the inventory target data 120 from the current date to the planned period end date from the inventory target data storage unit 12.

  Further, the control unit 21 acquires the previous (last week) production plan data 250 recorded in the production plan data storage unit 25 and determines the variable number. Specifically, the simulation selection means 212 of the control unit 21 extracts the production plan data 250 with the newest calculation date of the production plan data 250. Then, the simulation selection means 212 acquires the production system identifier for each week of the production plan data 250 and acquires the production system data 231 for this production system identifier. Next, the simulation selecting means 212 identifies the overtime day and the holiday work day from the maximum overtime number and the system maintenance day of the production system data 231 and the overtime flag of the production plan data 250. The simulation selection means 212 compares the specified overtime days and holiday work days with the overtime allowance condition data 233 and the leave allowance condition data 234, and can increase the maximum overtime days and holiday work days that can be increased per week. Is calculated. And the simulation selection means 212 adds the value which multiplied the number of overtime production or the number of holiday production to these overtime possible days and holiday work days, and calculates the number of possible production increases. Moreover, the simulation selection means 212 counts the overtime days and holiday work days included in the overtime flag of the production plan data 250 for each week, and calculates the overtime days and holiday work days. The simulation selection means 212 adds the value obtained by multiplying the overtime production number or the holiday production number to these overtime days and holiday work days, and calculates the number of production reductions possible.

  Next, the control unit 21 executes a fluctuation amount calculation process using the previous production plan and actual inventory (step S1-2). Specifically, the simulation selection unit 212 of the control unit 21 extracts the adjustment planned stock of the production plan data 250 on the point date immediately before the current date from the extracted production plan data 250 including the previous calculation date. Moreover, the simulation selection means 212 extracts the inventory performance data 240 including this point date. Then, the simulation selection unit 212 calculates the amount of fluctuation (inventory amount deviation) for the last week by subtracting the extracted adjustment planned stock from the number of actual stocks in the extracted actual stock data 240.

  Then, the control unit 21 determines whether or not the amount of change from the previous production plan is within the range of the changeable number (step S1-3). Specifically, the simulation selection means 212 of the control unit 21 compares the calculated variable number (number of possible production increases and number of possible production reductions) with the amount of fluctuation for the last week.

  Here, when the fluctuation amount for the last week is within the range of the variable number (in the case of “YES” in step S1-3), the control unit 21 executes a remaining holiday adjustment simulation process (step S1-4). Specifically, the simulation selection unit 212 of the control unit 21 instructs the remaining holiday adjustment simulation execution unit 213 to execute the simulation. In response to this, the remaining holiday adjustment simulation execution means 213 executes the remaining holiday adjustment simulation process.

  In this remaining holiday adjustment simulation process, the control unit 21 temporarily stores the production system identifier corresponding to each point date of the production plan data 250 calculated last week in the memory as the production system identifier of the production plan data 250 calculated this time. Specifically, the remaining holiday adjustment simulation executing means 213 temporarily stores the production system identifier on each point date of the production plan data 250 of the previous week in the memory as the production system identifier on this point date.

  Then, the control unit 21 performs a remaining holiday allocation process. Specifically, the remaining time adjustment simulation executing means 213 of the control unit 21 subtracts the normal production quantity of the stored production system from the stock target value to calculate the overtime production scheduled amount. And the remaining holiday adjustment simulation execution means 213 allocates a holiday working day when the overtime production amount at the weekend of each week is large. Even if this holiday work day is assigned, if there is a large amount of overtime production during the week, overtime days are assigned on that day or around that day. In this case, the overtime adjustment simulation execution means 213 allocates overtime days and holiday work days so as to match the overtime permission condition and the leave allowance condition, and associates the overtime flag corresponding to each overtime day in the memory in the memory. Memorize temporarily.

  Specifically, the overtime adjustment simulation execution means 213 adjusts the overtime days so that the overtime days are 10 times or less in one month, and adjusts so that the holiday work days are less than once a week. And assign work days for holidays. The overtime adjustment simulation execution means 213 sets the overtime flag to “0” when the overtime day and the holiday work day are not assigned on the point date, and exceeds when the overtime day is assigned. Set the work flag to “1”. Also, when a holiday work day is assigned to the point date, the overtime flag is set to “2”, and when a holiday work day and overtime day are assigned, the overtime flag is set to “3”. To do. The remaining time adjustment simulation execution means 213 temporarily stores the set overtime flag in the memory in association with the point date.

  Next, it is determined whether the variable number is within the target range (step S1-5). Here, the control unit 21 calculates the variable number and compares the variable number with the upper limit value and the lower limit value of the target range. Specifically, the simulation selection unit 212 of the control unit 21 acquires the production system data 231 of the production system identifier stored in the memory by the remaining holiday adjustment simulation execution unit 213. Next, the simulation selection means 212 compares the overtime days and holiday work days stored in the memory with the maximum number of overtime, the overtime allowance condition data 233 and the leave allowance condition data 234 of the acquired production system data 231, For each predetermined period (for example, one week), the maximum number of overtime days and holidays that can be increased and decreased are calculated. Then, the simulation selection means 212 adds the values obtained by multiplying the calculated increase / decrease maximum overtime days and holiday work days by the overtime production number and the normal production number of the production system data 231 respectively. Calculate the variable number (maximum increase and minimum decrease). Then, the simulation selecting unit 212 compares the calculated variable number of each week with the stored upper limit value and lower limit value of the target range.

  Here, when the number of possible fluctuations for each week is within the target range (in the case of “YES” in step S1-5), the control unit 21 executes a loss cost evaluation process (step S1-6). Specifically, the loss cost evaluation processing means 216 of the control unit 21 acquires the production system data 231 including the production system identifier temporarily stored in the memory. The loss cost evaluation processing means 216 calculates the loss cost using the loss cost calculation master data 224 corresponding to the production identifier, the loss cost calculation formula, and the production schedule (production system identifier and overtime flag) stored in the memory. Then, the control unit 21 compares the calculated loss cost with the evaluation reference value.

Here, when the calculated loss cost exceeds the evaluation reference value (in the case of “NG” in step S1-6), the control unit 21 executes the remaining holiday adjustment simulation process again (step S1-6).
Step S1-4). Specifically, the loss cost evaluation processing unit 216 of the control unit 21 instructs the remaining holiday adjustment simulation execution unit 213 to re-execute the simulation. In response to this, the remaining holiday adjustment simulation process is executed as described above. In this case, in the remaining holiday adjustment simulation process, a production schedule different from the production schedule stored in the memory is calculated. In the remaining holiday adjustment simulation process, the production system identifier and the overtime flag of the newly calculated production schedule are temporarily stored in the memory in association with each point date.

  On the other hand, when the calculated loss cost is equal to or less than the evaluation reference value (“OK” in step S1-6), the control unit 21 executes a review sheet creation process to be described later (step S1-14).

  On the other hand, when the fluctuation amount for the last week is out of the range of the variable number (in the case of “NO” in step S1-3), or when the variable number is out of the target range in the remaining holiday adjustment simulation process (step S1). In the case of “NO” in −5), the control unit 21 executes a system determination simulation process with the current variation specifications (step S1-7). Specifically, the simulation selection unit 212 of the control unit 21 gives a simulation execution instruction to the system determination simulation execution unit 214. In response to this, the system determination simulation execution means 214 acquires the production system identifier of the previous production plan data 250, multiplies the normal production number of this production system identifier by the working day of 1 week, Calculate the normal number of systems. Further, the system determination simulation execution means 214 compares the normal system number of one week with the total of the stock target values corresponding to this one week, and determines whether the production is increased or decreased based on the magnitude relationship.

  When it is determined that the stock target value is greatly increased, the system determination simulation execution unit 214 determines the production system specified in the fluctuation range data 232 with respect to the production system identifier temporarily stored in the memory (this embodiment). Then, the production system within “one stage” is selected, and the production system of each point date is determined so as to satisfy the system maintenance days. Specifically, the production system identifier of the production system in which the normal production quantity is increased by one stage from the production system of the previous production plan data 250 is acquired and temporarily recorded in the memory. Further, the system determination simulation execution means 214 temporarily stores a flag indicating that the production is increased in the memory.

  If it is determined that the production is to be reduced, the system determination simulation execution means 214 acquires the production system identifier of the production system in which the normal production quantity is decreased by one stage from the production system identifier temporarily stored in the memory. , Temporarily record in memory. In this case, the system determination simulation execution unit 214 temporarily stores a flag indicating that the production is reduced in the memory.

  And the control part 21 judges whether it is in the range of the stock target of a point date (step S1-8). Here, the control unit 21 compares the normal production number of the determined production system with the stock upper limit value and the stock lower limit value of the stock target data 120. Specifically, the simulation selection unit 212 of the control unit 21 acquires the working days of each week from the holiday calendar data 222 and counts the number of working days of each week. The simulation selection unit 212 obtains the normal number of production systems determined from the production system data 231 and multiplies the normal number by the number of working days in each week to calculate the number of production systems in one week. Next, the simulation selection unit 212 compares the system production number with the stock upper limit value and the stock lower limit value of the stock target data 120. And when this system production number is in the range of the stock upper limit value to the stock lower limit value, the simulation selecting means 212 determines that it is within the stock target range of the point date.

Here, when it is within the stock target range of the point date (in the case of “YES” in step S1-8), the control unit 21 executes a remaining holiday adjustment simulation process after the system change (step S1-9). The remaining holiday adjustment simulation process after the system change is performed by the same process as the above-described step S1-4. Specifically, the simulation selection unit 212 of the control unit 21 gives a simulation execution instruction to the remaining holiday adjustment simulation execution unit 213. In response to this, the remaining holiday adjustment simulation execution means 213 executes a remaining holiday adjustment simulation process. Here, the remaining holiday adjustment simulation execution means 213 uses the production system identifier specified in step S1-7 as the production system identifier of the production plan data 250 calculated this time. Then, the remaining holiday adjustment simulation execution means 213 uses the production system identifier 231 of the production system identifier to perform a remaining holiday allocation process, and specifies an overtime flag for each point date. Then, the remaining holiday adjustment simulation execution means 213 temporarily stores the production system identifier and the overtime flag in the memory in association with each point date.

  Then, after performing the remaining holiday allocation process, it is determined whether the variable number is within the target range (step S1-10). Specifically, similarly to step S1-5, the simulation selection unit 212 of the control unit 21 calculates the variable number of each week and compares it with the upper limit value and the lower limit value of the target range.

  Then, when the variable number of each week is within the target range (in the case of “YES” in step S1-10), the control unit 21 executes a loss cost evaluation process (step S1-11). Specifically, the loss cost evaluation processing unit 216 of the control unit 21 performs the loss cost evaluation process in the same manner as in step S1-6 described above.

  Here, if the loss cost evaluation exceeds the evaluation reference value (“NG” in step S1-11), the remaining holiday adjustment simulation process (step S1-9) after the system change is repeatedly executed. When the loss cost evaluation is equal to or less than the evaluation reference value (in the case of “OK” in step S1-11), the control unit 21 executes a review sheet creation process described later (step S1-14).

  On the other hand, when it is out of the stock target range of the point date (in the case of “NO” in step S1-8) or when the variable number in the remaining holiday adjustment simulation process after the system change is out of the target range (step In the case of “NO” in S1-10, the control unit 21 executes a non-specification simulation process (step S1-12). Specifically, the simulation selection unit 212 of the control unit 21 gives a simulation execution instruction to the specification change simulation execution unit 215. In response to this, the specification change simulation execution means 215 changes the production system data 231, overtime allowance condition data 233, and leave allowance condition data 234 of the variable spec data 223, while assigning a production system identifier and remaining days. Run. Specifically, the specification change simulation execution means 215 executes an overtime allowable days change process, a production system change process, and a remaining leave adjustment process.

Here, first, overtime allowable days are changed. Specifically, the specification change simulation execution means 215 determines the overtime hours from the production system identifier temporarily stored in step S1-7 so that the adjustment planned stock in the planning period falls within the range of the stock upper limit value to the stock lower limit value. calculate. In this case, the specification change simulation execution means 215 calculates a production schedule that satisfies the conditions of the other variable spec data 223 excluding the allowable overtime days and does not exceed the maximum allowable overtime days stored in the memory. Then, the specification change simulation execution means 215 calculates the number of productions by summing the normal production quantity and the overtime production quantity of the production system data 231 including the production system identifier of the calculated production schedule. Then, the specification change simulation execution means 215 calculates the adjustment planned stock by subtracting the sales plan number of the sales plan data 110 from the calculated production amount at each point date. The specification change simulation execution means 215 compares the adjustment scheduled stock with the stock upper limit value and the stock lower limit value of the stock target data 120. When the adjustment planned stock in the planning period falls within the range of the stock upper limit value to the stock lower limit value, the spec change simulation executing means 215 ends the non-spec simulation process.

  Here, even if the maximum number of days allowed for overtime is set, if the point date of the adjustment planned stock that exceeds the range of the stock upper limit value to the stock lower limit value remains, the spec change simulation execution means 215 performs the production system change processing. Do. Next, the specification change simulation execution means 215 specifies whether the point date of the adjustment scheduled stock outside the range of the stock upper limit value to the stock lower limit value is an increase or a decrease in production. Specifically, the specification change simulation execution means 215 determines whether a production increase flag or a production reduction flag is recorded in the memory in step S1-7.

  When the production increase flag is recorded, the specification change simulation execution means 215 acquires the production system identifier of the production system in which the normal production quantity increases by one stage from the production system temporarily stored in step S1-7. Record temporarily in memory. Further, when the production cut flag is recorded, the specification change simulation execution means 215 acquires the production system identifier of the production system in which the normal production quantity is reduced by one stage from the production system temporarily stored in S1-7. , Temporarily record in memory.

  Then, the specification change simulation execution means 215 calculates a production schedule using the fluctuation specification data 223 other than the production system change using the production system identifier of this production system, and temporarily stores it in the memory. Then, the specification change simulation execution means 215 calculates the number of productions on the point date from the production system and overtime flag of the temporarily stored production schedule and the production system data 231, and calculates the adjustment scheduled stock. Then, the specification change simulation execution means 215 determines whether or not the adjustment planned stock is in the range of the stock upper limit value to the stock lower limit value. When the adjustment planned stock in the planning period is within the range of the stock upper limit value to the stock lower limit value, the spec change simulation executing unit 215 ends the non-spec simulation process.

  On the other hand, when the point date of the adjustment scheduled stock that exceeds the range of the stock upper limit value to the stock lower limit value remains, the spec change simulation execution means 215 stores the production system and the fluctuation spec data 223 in the condition data storage unit 22. Use this to perform the remaining holiday allocation process. By this remaining leave allocation process, it is determined whether or not the adjustment planned stock within the planning period is within the range of the stock upper limit value to the stock lower limit value. If the adjustment scheduled stock is within the range of the stock upper limit value to the stock lower limit value, the non-spec simulation process is terminated.

  Here, when there is a day when the scheduled adjustment stock does not fall within the range of the stock upper limit value to the stock lower limit value, the control unit 21 performs the above-described overtime allowable day change using the changed production system. Thereafter, the overtime allowable days changing process, the production system changing process, and the remaining leave allocation process are repeatedly executed.

  When the out-of-spec simulation process ends, the control unit 21 executes a loss cost evaluation process (step S1-13). Specifically, the loss cost evaluation processing unit 216 of the control unit 21 performs the loss cost evaluation process in the same manner as in step S1-6 described above.

  Here, when the loss cost evaluation exceeds the evaluation reference value (“NG” in step S1-13), the remaining holiday adjustment simulation process after the system change (step S1-12) is repeatedly executed.

  When the loss cost evaluation is equal to or less than the evaluation reference value (“OK” in step S1-13), the control unit 21 executes a review sheet creation process (step S1-14). Here, the control unit 21 generates review sheet screen data including stock expected graph data, production schedule graph data calculated this week, and production schedule graph data calculated last week. Specifically, first, the output processing means 217 of the control unit 21 acquires the inventory target data 120 from the previous month to the planned period from the inventory target data storage unit 12. Further, the output processing means 217 acquires the inventory actual date of one month ago from the inventory actual data storage unit 24. The output processing unit 217 acquires the production plan data 250 calculated this week from the production plan data storage unit 25. Then, the output processing means 217 plans the inventory target value, inventory upper limit value and inventory lower limit value of the inventory target data 120 from one month before to the planning period, the actual number of inventory from one month before to the previous day, and the current date. Stock prospect graph data including the adjustment target stock of the stock target data 120 until the period is generated.

  Next, the output processing means 217 extracts the production plan data 250 including the calculated date within the past month. The output processing means 217 acquires the production system identifier and the overtime flag of the production plan data 250 including the point date of the same week as the calculated date from the extracted production plan data 250. Then, the output processing means 217 uses the acquired production system identifier and the overtime flag to generate data for displaying the number of productions by production system and remaining days within the past month. Specifically, the output processing means 217 acquires the normal production number of the production system data 231 of this production system identifier. When the acquired overtime flag is “1” or “2”, the output processing means 217 outputs the production number corresponding to this flag (in the case of the “1” overtime flag, “2” In the case of the holiday attendance flag, the normal production number) is acquired and specified as the overtime production number actually produced on the point date. Then, the output processing unit 217 adds the specified overtime production number to the acquired normal production number. In this case, the output processing means 217 adds “0” when the overtime flag is “0”. Then, production schedule graph data of past results including the normal production number of the production system of this week's production plan data 250 and the number of remaining days produced due to overtime is created.

  Further, the output processing means 217 acquires the previously calculated production plan data 250 and generates data for displaying the number of productions by production system and overtime. In this case, the output processing unit 217 obtains the production plan data 250 from the production plan data storage unit 25 with the date closest to the past in the past as the calculation date. Then, the output processing means 217 uses the acquired production system identifier and overtime flag to display the number of productions within the past one month as described above, and the production schedule calculated over the last week for each production system and overtime. Separately, data for displaying the production number is generated. Similarly, the output processing means 217 acquires the production plan data 250 calculated this time, and generates data for displaying the number of productions by production system and overtime of the production schedule calculated this week. Then, the output processing means 217 generates the production schedule graph data calculated this week by using the data that displays the number of productions within the past month and the data that displays the production number of the production schedule calculated this week. Further, the output processing means 217 generates the production schedule graph data calculated last week using the data indicating the number of productions within the past month and the data indicating the number of productions of the current production schedule.

  Then, the output processing means 217 generates the expected inventory graph data, the production schedule graph data calculated this week, the production schedule graph data calculated last week, the review sheet screen data including the production schedule determination button and the manual correction button. Is generated.

Thereafter, the output processing means 217 transmits this review sheet screen data to the manager terminal 26. The administrator terminal 26 displays the review sheet screen on the display based on the review sheet screen data. As shown in FIG. 5, the review sheet screen includes a stock forecast graph 60, a production schedule graph 70 for this week, and a production schedule graph 80 for last week.

  In the stock prospect graph 60 in FIG. 5A, the current stock from the current date to one month ago, the sales plan from the current date to the planning period, and the stock schedule based on the production schedule are shown as bar graphs. Further, the stock prospect graph 60 includes an inventory target value A, a stock lower limit value B and a stock upper limit value C from one month before to the end date of the planning period, and an adjustment planned stock D from about 2 months after the current date. Is included.

  Further, in the production schedule graph 70 of this week in FIG. 5B, the number of productions based on the production schedule calculated this week is displayed for each production system and overtime. In the last week's production schedule graph 80 in FIG. 5C, the number of productions according to the production schedule calculated last week is displayed for each production system and overtime. Further, the production schedule graphs 70 and 80 display the past actual production number and actual overtime production number from the calculation date.

  Then, the administrator checks the production schedule graph 70 of this week displayed on the review sheet screen, and selects the production schedule determination button on this screen when determining that the production schedule is acceptable. In this case, the manager terminal 26 transmits a production schedule determination instruction to the production schedule planning system 20. The control unit 21 of the production schedule planning system 20 records the production plan data 250 of this week temporarily stored in the memory in the production plan data storage unit 25. Specifically, the output processing means 217 of the control unit 21 calculates the number of production from the production system identifier and the overtime flag for each point date recorded in the memory and the production system data 231, and uses each sales forecast number to calculate each point. Calculate the adjusted inventory for the day. Then, the output processing means 217 generates the production plan data 250 including the production system identifier, the overtime flag and the adjustment planned stock for each point date with the current date as the calculation date, and stores it in the production plan data storage unit 25. Remember.

  Thereafter, the control unit 21 of the production schedule planning system 20 transmits this week's production plan data 250 to the production management system 30. Thus, the production schedule planning process is completed.

According to this embodiment, the following effects can be obtained.
In the present embodiment, in the system determination simulation process (step S1-7) with the current variation specifications, the control unit 21 creates a new production system based on the production system identifier of each point date of the previous production plan data 250. To decide. Then, the control unit 21 temporarily stores in the memory the production system identifier specified in step S1-7 as the production system identifier for each point date. Further, in the remaining holiday adjustment simulation process after the system change (step S1-9), the control unit 21 performs the remaining holiday allocation process, specifies the overtime flag for each point date, and temporarily stores it in the memory. Thereafter, when a production schedule determination instruction is received from the administrator terminal 26 via the review sheet screen, the control unit 21 produces production plan data including the production schedule (production system identifier and overtime flag) temporarily stored in the memory. 250 is recorded in the production plan data storage unit 25 and transmitted to the production management system 30. For this reason, the control unit 21 determines the current production system using the production schedule created last time, and automatically determines the overtime schedule that satisfies the overtime restriction condition in this production system. Therefore, a production schedule can be planned efficiently.

In the present embodiment, when the fluctuation amount for the last week is within the range of the changeable number (in the case of “YES” in step S1-3), the control unit 21 of the production schedule planning system 20 performs the remaining holiday adjustment simulation process ( Step S1-4) is executed. Here, the control unit 21 temporarily stores the production system identifier corresponding to each point date of the production plan data 250 calculated last week in the memory as the production system identifier of the production plan data 250 calculated this time. Then, the control unit 21 allocates overtime days and holiday work days so as to match the overtime permission condition and the leave permission condition, and associates the overtime flag corresponding to the overtime flag with the point date, and temporarily stores it in the memory. Perform the allocation process. For this reason, the control unit 21 calculates a new production schedule using the production system of the previous production plan as it is when the difference between the previous production plan and the actual inventory is within the range of variable numbers. A production schedule can be planned efficiently.

  -In this embodiment, the control part 21 performs the remaining holiday adjustment simulation process (step S1-4), the remaining holiday adjustment simulation process after a system change (step S1-9), or a non-spec simulation process (step S1-12). After performing, loss cost evaluation processing is performed (steps S1-6, S1-11, S1-13). Then, the calculated loss cost is compared with the evaluation reference value, and when the calculated loss cost exceeds the evaluation reference value (in the case of “NG” in steps S1-6, S1-11, and S1-13), the control unit 21 executes each simulation process again (steps S1-4, S1-9, S1-12). When the loss cost is equal to or less than the evaluation reference value (in the case of “OK” in steps S1-6, S1-11, and S1-13), the control unit 21 executes a review sheet creation process (step S1-14). When the production schedule determination instruction is received via the review sheet screen, the control unit 21 records the production plan data 250 of this week temporarily stored in the memory in the production plan data storage unit 25, and the production management system 30. Send to. For this reason, it is possible to perform production using a production schedule in which the loss cost is equal to or less than the evaluation reference value. Therefore, it is possible to efficiently plan a production schedule with a low loss cost.

  In the present embodiment, the point date is out of the target range (in the case of “NO” in step S1-8), or the remaining variable adjustment simulation processing after the system change is out of the target range In the case (in the case of “NO” in step S1-10), the control unit 21 executes a non-spec simulation process (step S1-12). In this case, the control unit 21 changes the production system data 231, overtime allowance condition data 233, and leave allowance condition data 234 for each point date using conditions different from the conditions of the fluctuation specification data 223. For this reason, the control unit 21 of the production schedule planning system 20 automatically changes the predetermined fluctuation specification data 223 and performs a production schedule planning process. Therefore, a production schedule can be planned efficiently according to the fluctuation of the inventory target.

  -In this embodiment, the control part 21 produces | generates the review sheet screen data containing stock expected graph data, and displays the review sheet screen on the administrator terminal 26. FIG. For this reason, the administrator can easily grasp changes in the current inventory plan, target value, inventory upper limit value, inventory lower limit value, and adjustment scheduled inventory by viewing the expected inventory graph 60 on the review sheet screen.

  In the present embodiment, the control unit 21 generates review sheet screen data including the production schedule graph data calculated this week and the production schedule graph data calculated last week, and causes the administrator terminal 26 to display the review sheet screen. . For this reason, the administrator can easily grasp the changed part of the production system by browsing the production schedule graphs 70 and 80 calculated this week and last week on the review sheet screen.

Moreover, you may change the said embodiment as follows.
In the above embodiment, when the control unit 21 of the production schedule planning system 20 determines whether or not it is within the stock target range of the point date (in the case of step S1-8), the production system for the determined last week And the stock upper limit (and stock lower limit) of the stock target data 120 were compared. In this case, the range of the stock target may be other than the stock upper limit value to the stock lower limit value. For example, the inventory target range may be determined by subdividing the inventory upper limit value to the inventory lower limit value (for example, in three stages) and depending on the tendency of the sales plan and the situation of the sales forecast number. Specifically, the control unit 21 includes table data for specifying a value serving as a standard for inventory and a range thereof according to a sales plan trend (production increase or decrease) and the number of sales forecasts. For example, if the number of sales forecasts is large and the possibility of production cuts is high, the target range will be the inventory target data from the lower inventory limit value. If the number of sales forecasts is large and the possibility of production increases is high, the target value will be Table data with the range as inventory target data is provided. The control unit 21 uses the table data to execute a simulation process that achieves a narrow range of inventory targets. For this reason, it is possible to devise a production schedule that provides a more appropriate inventory according to the number of sales forecasts and the tendency of sales forecasts.

  In the above embodiment, the specification change simulation execution unit 215 stores data related to the change order and the changeable number. The specification change simulation execution means 215 repeatedly performs the overtime allowable days change process, the production system change process, and the remaining days adjustment process in order, and changes the overtime allowance days and the fluctuation range of the variable specifications to execute the off-spec simulation. The variable specification change items, change order, and changeable number used in the off-spec simulation are not limited thereto. For example, in the case of a production reduction process, the specification change simulation execution means 215 may increase the number of holidays and perform a simulation using the holiday calendar as a change item.

  In the above embodiment, the production system data 231 includes data relating to the production system identifier, normal production quantity, overtime production quantity, maximum overtime count, and production maintenance days. Then, the production number was determined using the system identifier. This production system is not limited to the same production line, and a plurality of production lines can be assumed. Depending on the production line, there are many production preparation days but some lines can be produced in large quantities in a certain period, while others can produce only a small amount, but there are few production maintenance days. You may perform each simulation according to the characteristic of such a production line.

  In the above embodiment, the production schedule planning process is performed every week. Instead, it may be performed every day. In this case, it is possible to quickly cope with the fluctuation.

1 is a schematic diagram of a system in an embodiment. It is explanatory drawing of the data memorize | stored in the data memory | storage part, (a) is a sales plan data memory | storage part, (b) is an inventory target data memory | storage part, (c) is the data memorize | stored in the condition data memory | storage part. It is explanatory drawing of the data memorize | stored in the data storage part, (a) is an inventory performance data storage part, (b) is the data memorize | stored in the production plan data storage part. The flowchart for demonstrating the process sequence of a production schedule planning process. It is explanatory drawing of the graph contained in a review sheet | seat screen, (a) is an inventory forecast graph, (b) and (c) are the production schedule graph of this week of this week and last week.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Production sales monitor system, 11 ... Sales plan data storage part, 12 ... Inventory target data storage part, 20 ... Production schedule planning system, 21 ... Control part as control means, 22 ... Condition data storage part, 24 ... Inventory results Data storage unit 25 ... Production plan data storage unit 26 ... Administrator terminal 30 ... Production management system 110 ... Sales plan data 120 ... Inventory target data 211 ... Variable number specifying means 212 ... Simulation selection means 213 ... Remaining holiday adjustment simulation execution means, 214 ... System determination simulation execution means, 215 ... Spec change simulation execution means, 216 ... Loss cost evaluation processing means, 217 ... Output processing means, 221 ... Planned period data, 222 ... Holiday calendar data, 223 ... Fluctuating spec data, 224 ... Roscos Calculation master data, 231 ... production system data, 232
... fluctuation range data, 233 ... overtime allowance condition data, 234 ... leave allowance condition data, 240 ... inventory performance data, 250 ... production plan data.

Claims (4)

Inventory actual storage means for recording the actual number of actual inventory,
Control means connected to the inventory target value storage means for recording the inventory target range calculated from the sales plan and modified based on the actual inventory;
Production system conditions that store the system identifier that identifies the production system, the number of normal productions produced by normal working hours of this production system, the number of overtime productions produced by overtime, and the number of days this system is maintained Storage means;
Overtime limit storage means for storing overtime limit conditions regarding the upper limit of overtime;
A production schedule planning system comprising a production schedule storage means for storing a production schedule planning date, a production schedule system identifier and an overtime flag in association with each other,
The control means includes
Inventory target value acquisition means for acquiring an inventory target range from the inventory target value storage means ;
Obtaining the previous production schedule from the production schedule storage means;
The production identifies a system identifier contained in the schedule, acquires system maintenance days of these systems identifiers, number usually produced and the number of overtime production from the production system condition storage unit,
By subtracting the number of overtime in the previous production schedule from the upper limit value of overtime stored in the overtime limit storage means, the number of overtime that can be increased is calculated, and the overtime production is calculated for this overtime. Multiply the number to calculate the variable number,
Based on the total number of goods received in the production system of the previous production schedule and the number of goods received by summing the number of overtime production corresponding to the overtime flag in this schedule, the planned inventory quantity with the sales forecast number reduced is calculated as the previous production schedule. To calculate the amount of change from the previous production schedule,
When the fluctuation amount does not exceed the variable number, the production system in the previous production schedule is determined as the production system of the current production schedule,
When the fluctuation amount exceeds the variable number, a production system determining means for changing to a production system so as to satisfy the system maintenance days ;
Overtime determination means for determining overtime by allocating overtime below the limit of overtime to the normal production number of the determined production system so as to be in the inventory target range;
A production schedule planning system comprising plan recording means for recording the determined production system and the production schedule including the overtime in the production schedule storage means. Loss cost calculation parameter storage means for storing a parameter in which parameters for calculating the loss cost with respect to the production system and overtime are recorded;
The control means stores data relating to a loss cost calculation formula for calculating a loss cost of a production schedule and an evaluation reference value,
The control unit obtains the parameters related to the determined production system and overtime from the loss cost calculation parameter storage unit, calculates the loss cost by substituting it into the loss cost calculation formula, and compares the loss cost with the evaluation reference value. And further comprising loss cost evaluation means for performing loss cost evaluation,
If the loss cost evaluation by the loss cost evaluation means exceeds the evaluation reference value, the overtime determination means re-determines the overtime,
2. The production schedule according to claim 1 , wherein when the loss cost evaluation by the loss cost evaluation means does not exceed the evaluation reference value, the plan recording means records the production schedule in the production schedule storage means. Planning system. Inventory actual storage means for recording the actual number of actual inventory,
Control means connected to the inventory target value storage means for recording the inventory target range calculated from the sales plan and modified based on the actual inventory;
Production system conditions that store the system identifier that identifies the production system, the number of normal productions produced by normal working hours of this production system, the number of overtime productions produced by overtime, and the number of days this system is maintained Storage means;
Overtime limit storage means for storing overtime limit conditions regarding the upper limit of overtime;
A production schedule planning method using a system comprising a production schedule storage means for storing a production schedule planning date, a production schedule system identifier and an overtime flag in association with each other,
The control means includes
And inventory target value acquisition step for acquiring inventory target range from the inventory target value storing means,
Obtaining the previous production schedule from the production schedule storage means;
The production identifies a system identifier contained in the schedule, acquires system maintenance days of these systems identifiers, number usually produced and the number of overtime production from the production system condition storage unit,
By subtracting the number of overtime in the previous production schedule from the upper limit value of overtime stored in the overtime limit storage means, the number of overtime that can be increased is calculated, and the overtime production is calculated for this overtime. Multiply the number to calculate the variable number,
Based on the total number of goods received in the production system of the previous production schedule and the number of goods received by summing the number of overtime production corresponding to the overtime flag in this schedule, the planned inventory quantity with the sales forecast number reduced is calculated as the previous production schedule To calculate the amount of change from the previous production schedule,
When the fluctuation amount does not exceed the variable number, the production system in the previous production schedule is determined as the production system of the current production schedule,
When the amount of the variation exceeds the number of available said variations, so as to satisfy the system maintenance days, the production system determining step of changing the production system,
So that the stock target range, the limits following overtime of the overtime, assigning the normal production quantity of the determined production system, and overtime determination step of determining overtime,
A plan recording stage for recording the determined production system and the production schedule including the overtime in the production schedule storage means ;
The production schedule planning method characterized by performing . Inventory actual storage means for recording the actual number of actual inventory,
Control means connected to the inventory target value storage means for recording the inventory target range calculated from the sales plan and modified based on the actual inventory;
Production system conditions that store the system identifier that identifies the production system, the number of normal productions produced by normal working hours of this production system, the number of overtime productions produced by overtime, and the number of days this system is maintained Storage means;
Overtime limit storage means for storing overtime limit conditions regarding the upper limit of overtime;
A production schedule planning program in a system comprising a production schedule storage means for storing a production schedule planning date, a production schedule system identifier and an overtime flag in association with each other,
The control means;
Inventory target value acquisition means for acquiring an inventory target range from the inventory target value storage means;
Obtaining the previous production schedule from the production schedule storage means;
The production identifies a system identifier contained in the schedule, acquires system maintenance days of these systems identifiers, number usually produced and the number of overtime production from the production system condition storage unit,
By subtracting the number of overtime in the previous production schedule from the upper limit value of overtime stored in the overtime limit storage means, the number of overtime that can be increased is calculated, and the overtime production is calculated for this overtime. Multiply the number to calculate the variable number,
Based on the total number of goods received in the production system of the previous production schedule and the number of goods received by summing the number of overtime production corresponding to the overtime flag in this schedule, the planned inventory quantity with the sales forecast number reduced is calculated as the previous production schedule. To calculate the amount of change from the previous production schedule,
When the fluctuation amount does not exceed the variable number, the production system in the previous production schedule is determined as the production system of the current production schedule,
A production system determining means for changing to a production system so as to satisfy the system maintenance days when the fluctuation amount exceeds the variable number ;
Overtime determination means for determining overtime by allocating overtime below the overtime limit to the normal production quantity of the determined production system so as to be within the inventory target range, and the determined production system and A production schedule planning program that functions as a plan recording unit that records the production schedule including the overtime in the production schedule storage unit.

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