JP6659811B2 - Warehouse design system - Google Patents

Description

  The present invention relates to a technology for designing a facility such as a warehouse.

  BACKGROUND ART As a background art, there is JP-A-2001-195116 (Patent Document 1). This publication discloses a workplace optimization scheduling method and a workplace apparatus that can assign workplaces for manufacturing each product in a factory that performs heavy industrial products without any excess or shortage, and that can level the work load. It is the purpose. "(See abstract).

JP 2001-195116 A

  In the design work of a distribution warehouse, work is settled in the workable time zone, the cost is minimized, and an executable work schedule is drafted, and each time zone in each process from receiving to storage, picking, inspection, shipping is The amount of work and the number of resources (number of facilities, number of workers, etc.) are drafted. Also, the area of the area used in each process is designed, and each area is arranged in the warehouse layout.

  Patent Literature 1 describes a mechanism in which, when a plurality of work places where products can be manufactured are given, the occupancy of the work places is leveled and a production schedule that satisfies a delivery date is planned. However, Patent Literature 1 does not evaluate whether a temporary storage amount generated between processes, such as from the end of a picking process to the start of an inspection process, fits in a temporary storage area in a warehouse.

  Therefore, the present invention provides a method of drafting a work schedule in which the work falls within the workable time zone, the resources and the temporary storage amount fall in the work area and the temporary storage area, respectively, and the resource cost is minimized.

  In order to solve the above-described problems, one embodiment of the present invention is a warehouse design system that designs a warehouse to be carried out after performing a plurality of operations on a carried-in article, wherein the warehouse includes: The warehouse design system has a plurality of areas including a work area where the work of the process is performed, and a temporary storage area where articles between the processes are temporarily stored, and the warehouse design system is connected to the control unit and the control unit. A storage unit, wherein the storage unit is configured to output information indicating an amount of work performed on the article in each of the steps, productivity indicating an amount of work objects that can be processed per unit time in each of the steps, and the plurality of steps. , Information indicating the order of execution of the plurality of steps, information indicating the order of the steps, information indicating the amount of passing objects in the temporary storage area between steps, and layout information indicating the arrangement and area of each area And each of the above areas Information indicating the product margin rate, process use resource type information indicating the type of resource used in each step and the occupied area of the resource for each type, and the operating time zone of the resource for each type of shift Holding the shift information and the packing information indicating the occupied area of the article, the control unit controls the area of each area, the margin of the area of each area, and the occupied area per resource. , The upper limit of the resource amount in each area is calculated, the work amount of each step, the productivity indicating the amount of work objects that can be processed per unit time in each step, and the Based on the information indicating the workable time zone and the shift information, the total man-hours of each process are calculated, and the total man-hours of each process are divided and assigned to the workable time zones, Information indicating the amount of work for each time slot of each process so that all work of the process is performed in the workable time slot and resources of type and shift operating in each time slot are used. Generate a work schedule plan including, based on the work schedule plan, for each time period, calculate a work end ratio indicating the ratio of completed work of all the work of each of the steps, the work end ratio for each time zone By multiplying the difference between the work completion ratio of the previous process and the work completion ratio of the subsequent process by the amount of passing objects in the temporary storage area between the processes, based on the work completion ratio of each process and the process context information, Calculate the amount of the articles temporarily placed between the steps, and based on the amount of the articles temporarily placed between the steps and the packing information for each time zone, the temporary storage area between the steps for each time slot. Calculate the required area of A surplus amount or a shortage amount of each area is calculated based on a required area of each area and an area of each area included in the layout information, and a result is output.

  According to one embodiment of the present invention, it is possible to design a facility such as a warehouse capable of realizing a work schedule that satisfies conditions of delivery date and area.

It is explanatory drawing which shows the outline | summary of the flow of goods in the distribution warehouse of the Example of this invention. It is a block diagram showing composition of a warehouse design system of an example of the present invention. FIG. 4 is an explanatory diagram of a process information table according to the embodiment of the present invention. It is an explanatory view of a process order information table of an example of the present invention. FIG. 4 is an explanatory diagram of a resource type information table according to the embodiment of this invention. It is an explanatory view of a process use resource type information table of an example of the present invention. FIG. 5 is an explanatory diagram of a shift information table according to the embodiment of the present invention. It is an explanatory view of a resource hourly information table of an example of the present invention. It is an explanatory view of an area information table of an example of the present invention. It is an explanatory view of a packing state information table of an example of the present invention. FIG. 4 is an explanatory diagram of a work area area calculation master information table according to the embodiment of this invention. It is an explanatory view of a master information table for temporary storage area area calculation of an example of the present invention. It is explanatory drawing of the order delivery date information table of the Example of this invention. It is an explanatory view of a work quantity information table for every process of each order of an example of the present invention. It is explanatory drawing of the temporary storage area passing thing amount table for every process of each order of the Example of this invention. It is a flowchart which shows the process which the warehouse design system of the Example of this invention performs. It is a flowchart which shows the process which the work schedule proposal production | generation part of the Example of this invention produces | generates a work schedule proposal and a required resource number proposal. It is a flowchart which shows the process which the required area calculation part of the Example of this invention calculates a temporary storage area required area. It is a flowchart which shows the process which the work schedule proposal change part of the Example of this invention changes a work schedule proposal and a required resource number proposal. It is explanatory drawing which shows the example of output of the planning result by the warehouse design system of Example of this invention. It is explanatory drawing which shows the example of an output of the area area correction plan by the warehouse design system of the Example of this invention. It is explanatory drawing which shows the example of an output of the area accommodation plan by the warehouse design system of the Example of this invention. It is explanatory drawing which shows the example of output of the shortage area and the surplus area by the warehouse design system of the Example of this invention. It is explanatory drawing which shows the example of an output of the order reception time and the truck departure time of each order after the workable time zone change by the warehouse design system of the Example of this invention. It is an explanatory view showing an example of a user interface which a warehouse design system of an example of the present invention provides.

  Hereinafter, embodiments of the present invention will be described.

  FIG. 1 is an explanatory diagram showing an outline of a flow of goods in a distribution warehouse according to an embodiment of the present invention.

  Specifically, FIG. 1 shows an example of the layout of a distribution warehouse and the flow of goods from arrival to shipment in the distribution warehouse.

  First, the receiving operation is performed in the following flow, for example. The goods received from the receiving truck Tr1 stopped at the upper part of FIG. 1 (that is, the articles handled in the warehouse) are carried by the receiving worker and temporarily stored in the receiving / shipping berth area L1. The goods that have been received and temporarily placed in the receiving / shipping berth area L1 are also referred to as goods B1. Next, the goods B1 temporarily placed in the receiving / shipping berth area L1 are sequentially carried by the storage worker to the storage area L2, and stored in a predetermined position such as a goods shelf.

  Next, the shipping operation is performed in the following flow, for example. First, in accordance with a product shipping instruction, a pick worker picks (collects) a product from the storage area L2, transports the product to the temporary storage area L3 before inspection, and temporarily stores the product. The product temporarily placed in the temporary storage area L3 before inspection is also described as a product B2. Next, the commodities B2 temporarily placed in the pre-inspection temporary storage area L3 are sequentially carried by the inspection worker to the inspection work area L4 and inspected. Next, the commodities that have been inspected are sequentially carried to the receiving / shipping berth area L1 by the transport operator, and are temporarily placed in, for example, a row for each store until the shipping truck Tr2 arrives. The product temporarily placed in the receiving / shipping berth area L1 for shipping is also described as a product B3. Finally, the merchandise B3 temporarily placed in the receiving / shipping berth area L1 is packed into the shipping truck Tr2 by the shipping worker and leaves the warehouse.

  In this embodiment, for a warehouse as shown in FIG. 1, for example, in the case of receiving work, the arrival time of goods (that is, the work start time and the temporary placement occurrence time in the receiving berth area) is given. A work schedule that satisfies the area constraint that the work resources and the temporary storage amount can fit in the set layout area and the condition of the minimum resource cost is drafted and provided to the user.

  On the other hand, in the case of shipping work, the order receiving time from the delivery destination store or the like (that is, the work start time) and the truck departure time (that is, the delivery date / shipping deadline and the temporary storage end time at the shipping berth). Then, a work schedule that satisfies the area constraint that the work resources and the temporary storage amount can fit in the given layout area and the condition of the minimum resource cost is drafted and provided to the user.

  Of course, the present invention is not limited to the warehouse of FIG. 1 in layout and operation, but can be applied to factories, warehouses, port facilities, and the like having different layouts, operations, and receipt / shipment forms. Hereinafter, for the sake of simplicity, the embodiment will be described with respect to the above-described example of the shipping operation.However, the present invention is not limited to the example of the shipping operation, and the receiving operation, the operation from receiving to shipping is performed. The present invention can also be applied to continuous TC (Transfer Center, through-type warehouse or distribution center) work, or other factory production work.

  FIG. 2 is a block diagram showing the configuration of the warehouse design system according to the embodiment of the present invention.

  The warehouse design system 1 of the present embodiment is, for example, a computer having a control unit P1, a storage unit D1, an input unit I1, an output unit O1, and a communication unit T1 that are interconnected.

  The control unit P1 executes, for example, a program stored in the storage unit D1 to execute a work schedule draft generation unit P1-1, a required area calculation unit P1-2, an area satisfaction evaluation unit P1-3, and a work schedule draft change unit. The processor realizes the functions of P1-4, output unit P1-5, and layout correction plan generation unit P1-6. Therefore, in the following description, the processing executed by each unit in the control unit P1 is actually performed by the control unit P1 according to an instruction described in a program stored in the storage unit D1, and the storage unit D1, the input unit This is executed by controlling I1, the output unit O1, the communication unit T1, and the like. Details of the executed processing will be described later.

  The storage unit D1 is, for example, a storage device such as a semiconductor storage device and a hard disk drive, and includes a program executed by the control unit P1, data referred to in a process executed by the control unit P1, and a process executed by the control unit P1. Is stored. The storage unit D1 of the present embodiment includes at least a master information storage unit D1-1, an order information storage unit D1-2, and a planning result storage unit D1 as areas for storing data referred to or generated by the processing of the control unit P1. -3.

  The master information storage unit D1-1 includes, for example, a process information storage unit D1-11, a process context storage unit D1-12, a resource type storage unit D1-13, a process use resource type storage unit D1-14, and a shift information storage. A storage unit D1-15, an hourly resource information storage unit D1-16, an area information storage unit D1-17, a package information storage unit D1-18, and a required area calculation master D1-19 are stored. These include information for associating each process, temporary placement between processes, use area, resources, necessary area calculation master, and the like.

  The order information storage unit D1-2 stores order delivery date information D1-21 and order quantity information D1-22 including a work quantity for each process of each order and a temporary storage area passing quantity for each process. .

  The planning result storage unit D1-3 is provided with, for example, a planned work schedule and a required resource amount plan indicating the amount of resources required to be input to the system in order to perform work in accordance with the planned work schedule. A layout correction plan when a work schedule plan that can be realized by the layout cannot be obtained is stored. These include information for associating the planning result with the master information and order information used for the planning.

  In the following description, a resource that can be counted, such as a worker or a work machine (for example, a POS described later), is exemplified as a resource to be input to the system. Although described as several proposals, the present invention can be applied to a case where a resource of a type to be measured is input.

  The input unit I1 is, for example, a device such as a keyboard, a mouse, or a touch sensor that receives input of information by a user of the warehouse design system 1. The output unit O1 is, for example, an image display device that outputs information to a user of the warehouse design system 1. The communication unit T1 is an interface that is connected to the network N1 and communicates with another device (not shown).

  Next, each information table of the master information storage unit D1-1 of the storage unit will be described.

  The process information storage unit D1-11 stores, for example, a process information table M1 as information for specifying the productivity and the work area of each process.

  FIG. 3 is an explanatory diagram of the process information table M1 according to the embodiment of the present invention.

  The process information table M1 has columns for a process name M1-1, productivity M1-2, a work area name M1-3, and a master number M1-4 for calculating a work area area.

  In the process name M1-1, for example, names for identifying processes such as start, picking, inspection, and end are stored. In the productivity M1-2, a value indicating the productivity of each process, for example, a value indicating the amount of work objects that can be processed per unit time in the process is stored. The work area name M1-3 stores a name for identifying an area in which work of each process is performed. The work area area master number M1-4 stores the identification number of a master (see FIG. 11) used to calculate the area of the area necessary for performing the work of each process.

  In the example of FIG. 3, since the “start” and “end” steps do not include substantial work, the corresponding productivity M1-2, work area name M1-3, and work area area calculation master number M1-4 is blank. In this embodiment, since the work of the "picking" step is performed in the storage area, the corresponding work area name M1-3 and the master number M1-4 for calculating the work area are blank. Further, in this example, the productivity of the work of the “inspection” step is “50” (for example, the number of products that can be processed per hour), the work is performed in the inspection work area, and the work required for the work is performed. To calculate the area, the master with the master number “1” is referred to.

  The process context storage unit D1-12 specifies the context of each process (that is, the execution order of each process), the temporary storage area where the products temporarily placed between the preceding and subsequent processes are placed, and the packaging style of the product. As the information, for example, a process order information table M2 is stored.

  FIG. 4 is an explanatory diagram of the process order information table M2 according to the embodiment of this invention.

  The process context information table M2 has columns for a previous process name M2-1, a post-process name M2-2, a temporary storage area name M2-3, and a master number M2-4 for calculating a temporary storage area area.

  In the first record in the example of FIG. 4, “start” is stored in the previous process name M2-1 and “picking” is stored in the post-process name M2-2, and the temporary storage area name M2-3 and the temporary storage area area are calculated. The master number M2-4 is blank. This indicates that no temporary placement of commodities occurs between the start step and the picking step. In the second record, “Picking” is set as the pre-process name M2-1, “Inspection” is set as the post-process name M2-2, “Temporary storage area before inspection” is set as the temporary storage area name M2-3, and the temporary storage area area is set. “2” is stored in the calculation master number M2-4. This is because, after picking is completed, the goods to be inspected are temporarily placed in the temporary storage area before inspection, and the master with the master number “2” (see FIG. 12) is referred to in order to calculate the area required for the area. It is shown that it is done.

  The resource type storage unit D1-13 stores, for example, a resource type information table M3 as information of the resource type.

  FIG. 5 is an explanatory diagram of the resource type information table M3 according to the embodiment of this invention.

  The resource type information table M3 has a column of resource type M3-1. The resource type M3-1 includes a type of a resource (for example, a type of a normal worker or a person such as a folk man who operates a forklift), or a basket for transporting goods, for example, A value indicating a Point Of Sales system (hereinafter simply referred to as POS) or a type of an object such as a forklift used for inspection is stored.

  The process use resource type storage unit D1-14 stores, for example, a process use resource type information table M4 as information on resource types used in each process.

  FIG. 6 is an explanatory diagram of the process use resource type information table M4 according to the embodiment of this invention.

  The process use resource type information table M4 includes a process name M4-1 for identifying each process, a resource type name M4-2 indicating a type of a resource used in each process, and information necessary for each resource type. A required area M4-3 indicating the occupied area of the work area is provided.

  In some cases, a plurality of types of resources are used in one process, and in that case, a plurality of records are prepared for one process. In the example of FIG. 6, a normal worker and a basket are used as resources in the picking process. However, since the picking work is performed in the storage area, “0” is stored in the required area M4-3 corresponding thereto. Have been. In the inspection process, a normal worker and a POS are used as resources, and “2” is stored as a required area M4-3 for installing the POS.

  The shift information storage unit D1-15 stores, for example, a shift information table M5 as information on shifts (for example, operating hours of resources such as people or objects (machines)).

  FIG. 7 is an explanatory diagram of the shift information table M5 according to the embodiment of the present invention.

  The shift information table M5 includes a shift name M5-1 for identifying each shift, start / end times M5-2 and M5-3 of each shift, and start / end times M5-4 of the first break in each shift. , M5-5, and the start / end times M5-6, M5-7 of the second break in each shift.

  In the example of FIG. 7, the shift of “am” is from 8:00 to 12:00, and there is no break. The "full time" shift is from 8:00 to 17:00, with two breaks from 12:00 to 13:00 and from 15:00 to 15:30.

  The resource hourly information storage unit D1-16 stores, for example, a resource hourly information table M6 as hourly information of each resource (that is, cost unit price information).

  FIG. 8 is an explanatory diagram of the hourly resource information table M6 according to the embodiment of this invention.

  The resource hourly rate information table M6 has columns of a resource type name M6-1 indicating a resource type, a shift name M6-2 applied to each resource type, and an hourly rate M6-3 of each resource.

  There may be multiple shifts that can be applied to one resource type, and each shift may have different hourly rates. In the example of FIG. 8, a shift of morning, afternoon, full time, or night may be applied to a normal worker. And the hourly wage of the night shift is the highest.

  The hourly wage of items such as a basket and a POS is “0”, but an hourly wage larger than “0” may be set, for example, when these are rental items.

  The area information storage unit D1-17 stores, for example, an area information table M7 as information indicating a unit price of each area.

  FIG. 9 is an explanatory diagram of the area information table M7 according to the embodiment of this invention.

  The area information table M7 has columns of an area name M7-1 for identifying each area and a unit price M7-2 indicating a unit price (for example, a price per square meter) of each area.

  The package information storage unit D1-18 stores, for example, a package information table M8 as dimensional information for each package.

  FIG. 10 is an explanatory diagram of the package information table M8 according to the embodiment of this invention.

  The package information table M8 has columns of a package name M8-1 for identifying a package such as a basket or a pallet, a width M8-2 and a depth M8-3 of each package. Based on this information, it is possible to calculate the bottom area occupied when the goods in each package are placed in the work area or the temporary storage area.

  The required area calculation master D1-19 includes, for example, a work area area calculation master information table M9 and a temporary storage area area calculation master information table M10 as information of the work area area calculation master and the temporary storage area area master. Remember.

  FIG. 11 is an explanatory diagram of the work area area calculation master information table M9 according to the embodiment of this invention.

  The work area area calculation master information table M9 has columns for a master number M9-1 and an area area margin ratio M9-2 corresponding to each master number.

  FIG. 12 is an explanatory diagram of the temporary storage area area calculation master information table M10 according to the embodiment of this invention.

  The temporary storage area area calculation master information table M10 has columns for a master number M10-1, an area area margin ratio M10-2 and a package name M10-3 corresponding to each master number.

  The order delivery date information D1-21 stores, for example, an order delivery date information table F1 as delivery date information of each order.

  FIG. 13 is an explanatory diagram of the order delivery date information table F1 according to the embodiment of this invention.

  The order delivery date information table F1 has columns of order name F1-1, order reception time F1-2, and track departure time F1-3 for each order. During the time from the order reception time F1-2 of each order to the truck departure time F1-3, it is possible to perform the operation up to shipment of the product based on the order.

  The order physical quantity information D1-22 stores, for example, a work physical quantity table F2 for each process of each order as information of a work physical quantity for each process of each order and a temporary storage area passing quantity for each inter-process.

  FIG. 14 is an explanatory diagram of the work quantity table F2 for each process of each order according to the embodiment of this invention.

  The work quantity table F2 for each process of each order includes an order name F2-1 for identifying each order, a process name F2-2 for identifying a process applied to each order, and a work corresponding to each process of each order. There is a column of work quantity F2-3 indicating the quantity of the target.

  Here, the unit of the value of the work quantity F2-3 is a unit in which the work is performed. For example, when the work is performed for each case in which a predetermined number of products are packed, the number of cases processed in each process of each order is stored in the work quantity F2-3. When the work is performed for each line of the order, the number of lines of each process of each order is stored in the work quantity F2-3. When the work is performed for each item, the number of items included in each order is stored in the work quantity F2-3. When the work is performed for each order, “1” is stored in the work quantity F2-3.

  Since this work unit is the same as the work unit in the productivity M1-2 of the process information table M1, the value of the work quantity F2-3 of each process of each order and the productivity M1-2 corresponding to the process are included. Based on the values, the work amount (man-hours) of each process of each order is calculated (formula (2) described later), and the work amount is assigned to each time zone, whereby a work schedule plan can be drafted.

  FIG. 15 is an explanatory diagram of the temporary storage area passing material amount table F3 for each process of each order according to the embodiment of the present invention.

  The temporary storage area passing amount table F3 for each process of each order has columns of an order name F3-1, a preceding process name F3-2, a post-processing name F3-3, and a temporary storage area passing amount F3-4, and is stored. It is stored in the unit D1. Here, the unit of the value of the temporary storage area passing amount F3-4 is the number counted in the package of the temporarily stored product. For example, if the package of the temporarily placed commodities is a basket, the number of the baskets is stored in the temporary storage area passing amount F3-4.

  In the example of FIG. 15, the order identified by “order01” includes steps of “start”, “picking”, “inspection”, and “end”, and temporarily places between “start” and “picking”. The passing amount in the area is “0”, and the passing amount in the temporary storage area between “picking” and “inspection” and between “inspection” and “end” is “30”.

  The storage unit D1 of the present embodiment may further include layout information of a warehouse. For example, when the warehouse design system of the present embodiment is used to design a new warehouse, when the user operates the input unit I1 and inputs a warehouse layout as shown in FIG. 1, the layout information is stored in the storage unit. D1 is stored. Alternatively, when the warehouse design system of this embodiment is used for changing the layout of an existing warehouse, the current layout information of the existing warehouse is stored in the storage unit D1. Such layout information includes at least information indicating an arrangement and an area of each area, and the area is an area area of a given layout in a process described later. As a result of the processing described later, when the user changes the layout such as expansion or reduction of any area, the change is reflected in the layout information of the storage unit D1.

  FIG. 16 is a flowchart illustrating a process executed by the warehouse design system according to the embodiment of this invention.

  Hereinafter, the processing executed by the warehouse design system will be described with reference to FIG. Actually, a plurality of resource types may be applied to one process, for example, in the case of using two types of resources of an inspection worker and a POS which is an inspection machine in an inspection process. In the description above, for simplicity, an example is shown in which only one resource type is applied per process. Even when a plurality of resource types are applied to one process, the same processing as described below can be performed.

  First, the control unit P1 reads various types of master information D1-11 to D1-19 from the master information storage unit D1-1 of the storage unit D1 (S1-1).

  Next, the control unit P1 reads the order delivery date information D1-21 and the order physical quantity information D1-22 from the order information storage unit D1-2 of the storage unit D1 (S1-2).

  Next, the work schedule plan generation unit P1-1 of the control unit P1 generates a work schedule plan and a required resource number plan (S1-3). The details of this processing will be described later with reference to FIG.

  Next, the required area calculating unit P1-2 of the control unit P1 calculates the required area of the temporary storage area for each area when the work schedule plan of step S1-3 is adopted (S1-4). Details of this processing will be described later with reference to FIG.

  Next, the area satisfaction evaluation unit P1-3 of the control unit P1 compares the required area calculated in S1-4 with the area area of the given layout in the area information D1-17 read in S1-1. It is determined whether the required area of the area is equal to or smaller than the area area of the given layout (S1-5).

  If the result of this determination is Yes (that is, the required area is equal to or less than the area area of the given layout), it indicates that the temporarily placed area can always accommodate the temporarily placed commodities. In particular, when the required area is smaller than the area area of a given layout, the temporary storage area has a surplus. On the other hand, if the result of this determination is No (that is, the required area is larger than the area area of the given layout), the temporary storage area cannot accommodate products temporarily stored in at least one of the time zones. (That is, the temporary storage area is insufficient).

  If the result of the determination in S1-5 is Yes, the output unit P1-5 of the control unit P1 stores the work schedule plan and the required number of resources plan of S1-3 in the planning result storage unit D1-3 of the storage unit D1. And outputs it (S1-6).

  On the other hand, if the result of the determination in step S1-5 is No, that is, if the required area of at least one area is larger than the area area of the given layout, the control unit P1 determines whether a predetermined termination condition is satisfied. Is determined (S1-7).

  If the result of the determination in step S1-7 is No, the work schedule plan changing unit P1-4 of the control unit P1 changes the work schedule plan and the required resource number plan (S1-8). Details of this processing will be described later with reference to FIG.

  The control unit P1 continues to obtain a work schedule plan and a required number of resources plan in which the required area is equal to or less than the area area of the given layout in all the areas in step S1-5, or a predetermined end condition in step S1-7. Steps S1-4 to S1-5 are repeated until is satisfied.

  When the predetermined termination condition is satisfied, for example, when the number of repetitions of steps S1-4 to S1-5 reaches a predetermined maximum number of repetitions, the calculation time by the repetition of steps S1-4 to S1-5 is predetermined. Is reached, the number of areas determined to have not satisfied the area in step S1-5 or the shortage amount falls below the threshold, or at least one or more areas specified by the user For example, when the area is satisfied.

  If the predetermined termination condition is satisfied in step S1-7, the control unit P1 outputs an error indicating that a work schedule that can be realized with the given layout area area cannot be obtained (S1-9). Further, the control unit P1 outputs the work schedule at that time, the required number of resources, and each area area. At this time, the control unit P1 may output the work schedule plan with the smallest shortage of area, the required number of resources, and each area area up to that point. The user may change the layout of the warehouse based on each output area area so that the shortage of the area is resolved. By outputting a plan with the minimum area shortage, the amount of layout change can be suppressed.

  In step S1-3, the work schedule plan generation unit P1-1 generates a work schedule plan that satisfies the delivery date, that the resource fits in the work area, and that the resource cost is the minimum, and that the required number of resources at that time. Generate Specifically, the work schedule plan and the required resource number plan in step S1-3 can be generated by, for example, the procedure shown in FIG.

  FIG. 17 is a flowchart illustrating a process in which the warehouse design system according to the embodiment of the present invention generates a work schedule plan and a required resource number plan.

  First, the work schedule draft generation unit P1-1 calculates the work area area of the given layout, the required area M4-3 per process use resource type in the process use resource type information table M4, and the master number M1- The upper limit of the number of resources in each work area is calculated by Expression (1) based on the area margin ratio M9-2 corresponding to No. 4 (S2-1).

  Upper limit of the number of resources = work area area / work area area margin ratio / required area per resource (1)

  Next, the work schedule draft generation unit P1-1 can calculate the total man-hour for each process of each order based on the various master information D1-11 to D1-19 and the various order information D1-21 and D1-22. An initial work schedule draft is generated by dividing and assigning the time slots (S2-2). Here, the workable time zone to be assigned is included in the time zone from the order reception time of each order to the truck departure time, and is included in the workable time zone of each process, and This is a time zone that is also included in the workable time zone of the shift of the resource to be used (that is, a time zone of all overlapping portions thereof). Further, in step S2-2, the work schedule draft generation unit P1-1 may assign a leveled man-hour for each order to the workable time zone, or may assign a random man-hour (total of all the workable time zones). (So that the value is the same as the total man-hour for each process of each order). As a result, all the operations of all the processes of each order are performed in the operable time zone of the order, and the type and shift resources operating (ie, operable) in each time zone are used. Then, a work schedule draft is created.

  Here, the total man-hour for each process of each order is calculated by the following equation (2) and stored in the storage unit D1. Equation (2) shows an example in which the work unit is a pallet. However, the calculation can be similarly performed for another work unit such as a container, a case, or a lot.

  Total man-hours in process B of order A [MH] = total work load in process B of order A [pallet] / productivity of process B [pallet / hr] (2)

  Next, the work schedule plan generation unit P1-1 calculates an initial required resource number plan necessary to realize the initial work schedule plan in step S2-2 (S2-3). At this time, when there are a plurality of shifts of resources to be used in each step and the hourly rates are different, resources of shifts with lower hourly rates may be preferentially allocated.

  Next, the work schedule plan generation unit P1-1 determines whether the required number of resources calculated in step S2-3 is within the upper limit calculated in step S2-1 (S2-4). If the result of this determination is Yes (that is, the required number of resources is within the upper limit), it means that the required area of the resources used in each step does not exceed the area of the given work area in any time zone. That is, it indicates that the resources used in each step can be accommodated in the work area. In particular, when the number of required resources is smaller than the upper limit, there is a surplus in the work area. On the other hand, if the result of this determination is No (that is, the required number of resources exceeds the upper limit), the required area of the resources used in any process at least in any one of the time zones is equal to the area of the given work area. This indicates that the resource used in any process cannot be accommodated in the work area (in other words, the work area is insufficient).

  If the result of the determination is Yes, the process proceeds to the next step S2-6. On the other hand, if the result of the determination in step S2-4 is No, that is, if the required number of resources exceeds the upper limit, the work schedule draft generation unit P1-1 corrects the schedule draft in step S2-2 ′, The processing after S2-3 is executed.

  In step S2-4, the work schedule plan generation unit P1-1 further determines whether a predetermined end condition is satisfied. This termination condition is a condition for terminating the process of calculating the work schedule plan even though a work schedule plan in which the required number of resources does not exceed the upper limit has not been calculated yet. For example, when the number of repetitions of steps S2-2 ', S2-3, and S2-4 reaches a predetermined number, it is determined that the predetermined end condition is satisfied.

  If the predetermined termination condition is satisfied in step S2-4, a work schedule draft in which the required number of resources does not exceed the upper limit has not been finally calculated. An error is output indicating that a possible work schedule is not obtained (S2-5). Further, the work schedule plan generation unit P1-1 outputs the work schedule at that time, the required number of resources, and the required area of each work area. At this time, the work schedule plan generation unit P1-1 may output the work schedule plan with the smallest area shortage up to that point, the required number of resources, and the required area of each work area.

  The work schedule draft generation unit P1-1 may execute the processing after step S1-4 in FIG. 16 by using the work schedule draft and the required number of resources draft output here, or the user may output the processing here. The layout of the warehouse may be changed so as to eliminate the shortage based on the required area of each work area. By outputting the plan with the minimum area shortage, the amount of layout change can be suppressed.

  Next, the work schedule plan generation unit P1-1 calculates the initial cost by the following equation (3) based on the initial required number of resources calculated in step S2-3 and the hourly wage of each resource. (S2-6).

  Next, the work schedule plan generation unit P1-1 determines whether a predetermined end condition is satisfied (S2-7). If the result of the determination in step S2-7 is No, the work schedule plan generation unit P1-1 converts the initial work schedule plan in S2-2 (or the work schedule change plan generated in the previous step S2-2 ″). A part of the schedule is changed to generate a work schedule change plan (S2-2 ″). After that, the work schedule draft generation unit P1-1 repeats steps S2-3, S2-4, S2-6, and S2-2 ″ until a predetermined termination condition is satisfied, and the work schedule draft with lower cost and the necessary Search for a proposed number of resources.

  The predetermined end condition in step S2-7 is a condition for terminating processing for calculating a lower-cost work schedule plan when a work schedule plan in which the required number of resources does not exceed the upper limit is calculated. . For example, when the number of repetitions of the step reaches a predetermined number, when the calculation time by the repetition of the step reaches a predetermined time, or in step S2-6, the initial resource cost or the changed resource cost is equal to or less than the threshold. May be determined that the predetermined termination condition is satisfied.

  If the result of the determination in step S2-7 is Yes (that is, the end condition is satisfied), the work schedule draft generation unit P1-1 finishes the work of all the processes in the workable time zone and makes it necessary. Among the combinations of several work schedule plans whose resource numbers do not exceed the upper limit and the required resource number plans, the one with the lowest cost is output and the process ends (S2-8).

  As described above, the work schedule plan generation unit P1-1 calculates the resource cost in step S2-6 and minimizes the resource cost by repeating S2-2 ″ to S2-6. )), The area cost can also be minimized by using the following equation (3 ′).

  The processing from step S1-4 onward in FIG. 16 is executed on the work schedule plan and the required resource number plan output in step S2-5 or step S2-8. In step S1-4, the required area calculation unit P1-2 calculates the temporary storage amount in each time zone when the work schedule plan in step S1-3 is adopted by simulation, and calculates the temporary storage area from the calculated temporary storage amount. Is calculated for each area. Specifically, the required area of the temporary storage area in step S1-4 can be calculated by, for example, the procedure shown in FIG.

  FIG. 18 is a flowchart illustrating a process in which the necessary area calculation unit P1-2 calculates the temporary storage area required area according to the embodiment of this invention.

  First, the required area calculation unit P1-2 calculates a work end ratio indicating a ratio of the work amount completed by each time period to the total work amount of each process of each order by using the equation (4) (step S3). -1).

  Next, the necessary area calculation unit P1-2 calculates the temporary object amount between the previous step i and the subsequent step i + 1 by using the equation (5a) (step S3-2).

  However, the temporary storage quantity (t) of order j between the pre-process i and the post-process i + 1 is calculated by equation (5b).

  Temporary storage quantity (t) of order j between pre-process i and post-process i + 1 = (work completion ratio of pre-process i of order j (t)-work completion ratio of post-process i + 1 of order j (t)) x Passage amount of temporary storage area of order j (5b)

  Finally, the required area calculation unit P1-2 uses the information in the temporary storage area area calculation master information table M10 and the corresponding information in the package information table M8 to temporarily store the information between the pre-process i and the post-process i + 1. The required area for the placing area is calculated by the equation (6a) (step S3-3). Here, although omitted for simplicity of notation, the temporary placement in the equation (6a) is a temporary placement between the preceding step i and the succeeding step i + 1. Thus, the maximum value of the temporary storage area required area between processes for each time zone is calculated as the temporary storage area required area between the processes.

  Here, T is the end time of all the work, and the required area (t) of the temporary storage area is calculated by Expression (6b).

  Temporary storage area required area (t) = area area margin factor x f (temporary storage amount (t), width of package, depth of package) (6b)

  Here, f indicates an arbitrary function using the temporary storage amount (t), the width of the package, and the depth of the package as variables.

  Through the above steps, the required area calculation unit P1-2 can determine the required area for the temporary storage area.

  In step S1-8 in FIG. 16, the work schedule draft changing unit P1-4 determines whether the temporary storage object amount overflowed from the temporary storage area in step S1-5 (that is, in step S1-5, the required area is the area of the given layout). The work schedule and the required number of resources are changed so that the amount of the temporary storage area determined to exceed the area falls within the area. This change is performed by paying attention to the fact that the amount of temporary objects between processes changes in conjunction with the amount of work in preceding and succeeding processes. For example, the amount of temporary storage can be reduced by reducing the amount of work in the preceding process or increasing the amount of work in the subsequent process. Specifically, the change of the plan in step S1-8 can be calculated by, for example, the procedure shown in FIG.

  FIG. 19 is a flowchart illustrating a process in which the work schedule plan changing unit P1-4 according to the embodiment of the present invention changes the work schedule plan and the required resource number plan.

  For the temporary storage area where the temporary storage amount overflows, the overflow time t is t = τ, the preceding process is process i, and the subsequent process is process i + 1.

  First, the work schedule plan changing unit P1-4 selects a pre-process or a post-process as a process to be adjusted (step S4-1).

  Next, the work schedule plan changing unit P1-4 selects one order j in which t = τ is included in the workable time zone in the selection process (step S4-2).

  Next, the work schedule plan change unit P1-4 reduces the work amount at t = τ of the order j of the selection process if the selection process is the previous process, and increases the work amount if the selection process is the subsequent process (step S4-3). Here, the decrease amount or the increase amount is a predetermined unit amount.

  By changing the amount of work in the selection process of order j as described above, the work in the post-process is completed beyond the completion ratio of the work in the previous process (that is, the product in which the work in the previous process is not completed) In some cases, a work schedule draft is created such that the work in the post-process for the first is completed first). However, in reality, a post-process operation cannot be performed on a product for which a pre-process operation has not been completed, so that such a schedule is not executable. The work schedule plan changing unit P1-4 inductively adjusts the work amount of the preceding and succeeding processes so that an executable schedule plan is created.

  Specifically, when the selected step is the previous step i, the work schedule plan changing unit P1-4 determines whether the work end ratio of the post-process i + 1 exceeds the work end ratio of the previous step i after the work amount is reduced. It is determined whether or not (step S4-4), if not exceeded (in the case of No), if it is exceeded (in the case of Yes), the work completion ratio of the post-process i + 1 is also reduced so as not to exceed (in the case of Yes) ( Step S4-5). The work schedule plan change unit P1-4 performs the same processing as described above, and furthermore, the work end ratios of all the post-processes up to the post-process i + 2, the post-process i + 3,. Repeat until the work end ratio does not exceed.

  Similarly, when the selected step is the post-process i + 1, the work schedule plan changing unit P1-4 determines whether the work end ratio after the increase in the work amount of the post-process i + 1 exceeds the work end ratio of the previous process i. It is determined (step S4-4), and if not exceeded (in the case of No), the process is terminated. If it is exceeded (in the case of Yes), the work completion ratio of the preceding process i-1 is also increased so as not to exceed (step S4-4). Step S4-5). The work schedule plan change unit P1-4 performs the same processing, and ends the work of all the subsequent processes up to the previous process i-2, the previous process i-3,..., The previous process 0 (start process). Repeat until the ratio does not exceed the work end ratio of the previous process.

  In the above procedure, at the time when the amount of temporary storage objects overflows, the work schedule is changed, such as reducing the work amount of the immediately preceding process or increasing the work amount of the immediately succeeding process. This is merely an example of the schedule change, and it goes without saying that the work schedule may be changed by other methods. For example, the work schedule may be changed by simultaneously adjusting the work amount of the preceding and succeeding processes, or simultaneously reducing or increasing the work amount over the previous process or the further process. In addition, the amount of work may be simultaneously reduced or increased over the previous time or the later time. In this way, it is not possible to increase the range of simultaneous changes by adjusting the amount of work only in the preceding and following processes or only at the relevant time, for example, the work area is insufficient and the number of resources cannot be increased, or the delivery time of the order cannot be met. It is effective when there is a problem.

  Next, an output example of the above processing result will be described.

  FIG. 20 is an explanatory diagram illustrating an output example of planning results by the warehouse design system according to the embodiment of this invention.

  Specifically, FIG. 20 is an example of a screen displayed by the output unit O1 to output the result of the processing described with reference to FIGS. In this screen example, as the work schedule plan, a plan of the amount of work to be allocated at each time is displayed in the window W1, a plan of the required number of resources is displayed in the window W2, a plan of the required area is displayed in the window W3, and the cost at that time is displayed in the window W4. Example), respectively.

  The draft of the work amount allocated at each time displayed in the window W1 is an example of the schedule plan output in step S1-6 (FIG. 16), and the work amount allocated to each process of each order for each time period. Including the display of. These work amounts are generated by allocating the total man-hours of each process calculated in S2-2 of FIG. 16 to each time zone, and corrected in S2-2 'or S2-2 "as necessary. For example, the amount of work related to operations such as picking and inspection is the number of people, and in the example of FIG. 20, five people are assigned to the picking of the order name “Order01” in the time zone from 8:00 to 8:30. No one is assigned to the inspection of the same order. In the time period from 8:30 to 9:00, five people are assigned to picking and inspection of the same order.

  The proposed number of required resources displayed in the window W2 is an example of the proposed number of resources output in step S1-6, and corresponds to the allocated work amount displayed in the window W1. Here, the maximum value of the number of required resources for each resource type and each shift for each time period of the day is displayed as the required number of resources. In the example of FIG. 20, the normal workers of the morning shift and the afternoon shift are displayed, but another type (or another shift) of a worker may be included, and a machine such as a POS or a forklift is included. It may be.

  The required area plan displayed in the window W3 is calculated based on the provisional area necessary area plan calculated in S1-4 and the resource number plan based on the resource number plan output in step S1-6. Includes proposed work area required area.

  The cost displayed in the window W4 is the total cost calculated based on the resource number plan output in step S1-6. This cost can be calculated based on the hourly wage corresponding to the allocated work amount, the allocated resource type, and the shift at each time displayed in the window W1 with reference to the resource hourly wage information table M6 (FIG. 8). .

  Further, since the data of the productivity M1-2 used in the equation (2) depends on the warehouse layout in the case of the transport process, the work schedule draft generation unit P1-1 uses the warehouse layout to transfer the route between the areas. May be predicted, the transport time between the areas is predicted from the length of the transport path and a predetermined (for example, a user preset) transport speed, and the productivity value predicted from the transport time may be used. The predicted value of the productivity of the transport process is calculated by the equation (7a). Note that, like Expression (2), Expression (7a) shows an example in which the work unit is a pallet. However, calculation can be similarly performed for other work units such as containers, cases, or lots.

  Predicted value of productivity of the transport process [pallet / hr] = transported material amount per transport "pallet" / inter-area transport time [hr] (7a)

  However, the inter-area transfer time [hr] is calculated by equation (7b).

  Area-to-area transport time [hr] = transport path length [m] / transport speed [m / hr] (7b)

  The shortest transport route between the areas in the warehouse layout may be obtained by the Euclidean distance or Manhattan distance when there is no obstacle or can be ignored, or by the Dijkstra method when the obstacle cannot be ignored. In addition, when the transport speed is different at each point in the warehouse due to the presence or absence of an obstacle or a difference in speed limit, the transport speed may be set individually for each area or each coordinate.

  For example, for a layout plan of a new warehouse or a layout change plan of an existing warehouse, the productivity shown in FIG. 16 to FIG. 19 is calculated in consideration of the transfer time as described above, and the layout plan is changed based on the result. In this case, the productivity is calculated again taking the transfer time into consideration as described above for the layout plan after the change, and the processing in FIGS. 16 to 19 is performed to take the transfer time between the areas into consideration. It is possible to draft a warehouse layout plan based on a more realistic work schedule plan.

  When the control unit P1 outputs an error indicating that a feasible work schedule cannot be obtained in step S1-9, the following information may be output together. An example of a screen displayed by the output unit O1 at the time of error output will be described with reference to FIGS.

  FIG. 21 is an explanatory diagram showing an output example of an area area correction plan by the warehouse design system according to the embodiment of the present invention.

  In the window W5 of FIG. 21, the work schedule plan and the required resource number plan with the smallest shortage of area and the required area when those plans are adopted are displayed as area area correction plans.

  In the example of FIG. 21, the required area plan calculated from the work schedule plan and the required number of resources plan and the layout area are displayed for each work area and temporary storage area. The required area plan is the same as that displayed in the window W3 in FIG. The area on the layout is a given area of each area. For example, at the stage of designing a new warehouse, if the above-mentioned warehouse design system is processed for the design data of the warehouse, the layout area is obtained from the warehouse design data at that time. Area of each area. Further, when the required area plan is larger than the layout area, the required area plan is displayed as an area correction plan.

  FIG. 22 is an explanatory diagram illustrating an output example of an area accommodation plan by the warehouse design system according to the embodiment of this invention.

  In the window W6 of FIG. 22, an area accommodation plan and an area required area where the area is shared in a plurality of processes are displayed, and a window W7 displays the occupation status of the temporary storage in the time series after the accommodation. .

  Here, the merit of considering the area accommodation plan is that the required area can be reduced by sharing the area between different processes in different time zones having a high area occupancy rate. For example, as shown in FIG. 22, in the case of a warehouse where arrivals are concentrated in the morning and shipments are concentrated in the night, the temporary storage area used for arrival and shipment is set to the same “shipment / shipment berth” area. A part of the temporary storage area is used as the temporary storage area after arrival during the time when the temporary storage amount is large after arrival and as part of the temporary storage area before shipment during the time when the temporary storage amount before shipment is large. You may. In this way, the area occupancy can be leveled by sharing (time sharing) an area with two temporary storage areas. As a result, the required area can be significantly reduced as compared with the case where the temporary storage areas are prepared for each of the arrival and the shipment.

  Specifically, in the window W6, as an example, a temporary storage area after arrival in which articles immediately after arrival, and articles waiting to be loaded on a truck for shipping are temporarily placed. The required area before accommodation of the temporary storage area before shipment is displayed. The required area before accommodation is a temporary area required area calculated in S1-4 based on the resource number plan output in step S1-6, similarly to the one displayed in the window W3 in FIG. Is the value of In the example of FIG. 22, the required area before accommodation of the temporary storage area after arrival and the temporary storage area before shipment are 2000 and 2800, respectively, so that the total of both is 4800. However, these values are the maximum values of the required area calculated for each time zone, as described in step S1-4. For this reason, if the time zone in which both values are maximum is different, the maximum value of the total value of both is smaller than the value obtained by simply summing the maximum values of both.

  For example, as shown in a window W7, the peak of the required area of the temporary storage area after arrival appears in the early morning to afternoon time zone, whereas the peak of the required area of the temporary storage area before shipment is late in the afternoon. In the case of appearing in the belt, all of these temporary storage areas are provided in the receipt / shipment berth area L1 to enable the interchange between them, so that the maximum value of the total of both is smaller than 4800 (2800 in the example of FIG. 22). ), And this is displayed as the required area after the window W6 is accommodated.

  By outputting the information as shown in FIG. 22, it is possible to propose an inter-area exchange plan effective for reducing the required area.

  FIG. 23 is an explanatory diagram illustrating an output example of a shortage area and a surplus area by the warehouse design system according to the embodiment of this invention.

  In the window W8 of FIG. 23, a list of a lacking area, which is an area having an insufficient area, and a surplus area, which is a surplus area, is displayed. In the example of FIG. 23, the receipt / shipment berth area is displayed as a shortage area, and the inspection work area is displayed as a surplus area.

  For example, a lack area may be displayed in a red color and a surplus area may be displayed in a blue color on the layout diagram. At that time, the shading of the color may be changed according to the shortage ratio / surplus ratio, which is the ratio of the layout area to the required area. When the adjacent areas on the layout are the missing area and the surplus area, respectively, a plan for recommending replacement of the surplus area with the insufficient area may be output and may be recommended and displayed on a map or the like.

  In the example of the window W9 in FIG. 23, since the receiving / shipping berth area is insufficient and the inspection work area has a surplus, the shortage area adjacent to the receiving / shipping berth area in the inspection work area is replaced with the replacement recommended area. Will be displayed as

  FIG. 24 is an explanatory diagram illustrating an output example of the order reception time and the truck departure time of each order after the change of the workable time zone by the warehouse design system according to the embodiment of this invention.

  As a result of performing the processing shown in FIGS. 16 to 19, even if a feasible work schedule is not created, the reception time of any order is moved forward or the departure time of the truck is moved backward. As a result, the time period during which the work is performed fluctuates, and a feasible work schedule can be created.

  For this reason, the control unit P1 creates a change plan of the order in which at least one of the reception time of at least one order and the truck departure time of at least one order is moved forward, and the change plan is created. 16 to 19 are executed based on this, and when a work schedule that can be realized with a given area is obtained, the work schedule and the order reception time / track departure time of each order are output.

  In the window W10 of FIG. 24, the reception time before the change, the departure time before the change, and the change when the work schedule feasible with the given area area is obtained based on the order change proposal. The later received time plan and the changed departure time plan are displayed. The user (ie, the warehouse designer) can present such a proposed change to the warehouse user and, if accepted, thereby omit the warehouse layout change.

  When the above methods are combined, for example, a user interface as shown in FIG. 25 is provided.

  FIG. 25 is an explanatory diagram of an example of a user interface provided by the warehouse design system according to the embodiment of this invention.

  Specifically, FIG. 25 illustrates an example of a screen output by the output unit O1. When the user operates the input unit I1 to input various information according to the display on the screen, the result is reflected on the display.

  For example, when the user designs a warehouse layout on the user interface shown in FIG. 25, a layout diagram showing the result is displayed in the window W11. According to this layout, the control unit P1 calculates the predicted value of the productivity of the transport process by the formula (7a) and the formula (7b) in the background process, and also calculates the predicted value of the productivity in the background process. A work schedule is prepared according to the flow of 16. Thus, whether or not each area of the warehouse layout designed by the user satisfies the required area and the cost at that time are evaluated in real time, and the sufficiency status (window W12 in FIG. 25), the accommodation plan and the shortage / The surplus situation (window W13 in FIG. 25) can be visualized and displayed on a table or a layout diagram, and the cost can be displayed (window W14 in FIG. 25).

  In this example, windows W13 and W14 are the same as those shown in window W9 of FIG. 23 and window W4 of FIG. 20, respectively. In the window W12, in addition to the necessary area plan and the layout area similar to the window W5 in FIG. 21, a sufficiency status indicating a surplus amount or a shortage amount of the layout area is displayed.

  The user can correct the layout plan with reference to the result visualized and displayed as described above. For example, when a correction to add the replacement recommended area of the inspection work area to the receipt / shipment berth area is input on the user interface, a layout diagram with the correction is displayed in the window W11. Further, in accordance with the modified layout, the control unit P1 updates the predicted value of the productivity of the transport process by the equations (7a) and (7b) in the background processing, and similarly updates the updated productivity in the background processing. Using the predicted values, a new work schedule is drawn up in the flow of FIG. 16, and the updated windows W12 to W14 can be output based on the new work schedule.

  The above processing can be performed not only when designing a new warehouse, but also when changing the layout of an existing warehouse.

  As described above, the warehouse design system according to the embodiment of the present invention generates a work schedule plan that satisfies a delivery date, a resource fits in a work area, and has a minimum resource cost, and a temporary storage amount when the plan is implemented. Is calculated by simulation, and the area required to store the temporary storage amount is calculated. If the area of the given layout is smaller than the required area, the work schedule is adjusted so that the temporary storage amount falls within the area, and reevaluation is performed. As a result, it is possible to formulate a work schedule that satisfies the delivery date, that the resources and the temporary storage amount fall within the work area and the temporary storage area, respectively, and that minimizes the resource cost. If such a work schedule cannot be established, the layout can be changed so that an appropriate layout can be designed.

  In the above embodiment, the example in which the present invention is applied to the shipping work of the distribution warehouse has been described.However, the present invention has a plurality of steps for the goods which are carried in, and the temporary placement of the articles occurs between the steps, The present invention can be widely applied to various facilities such as general warehouses, factories, port facilities, and the like, from which the article after the step is carried out. For example, the present invention can be applied to a production schedule planning work in a factory where the area of the temporary storage area is limited by setting the order receiving time and the truck departure time to the factory input date and the delivery date, respectively. it can.

In addition to what is described in the claims, the following are typical examples of aspects of the present invention.
(1) A warehouse design system for designing a warehouse to be carried out after performing a plurality of operations on a carried-in article,
The warehouse has a plurality of areas including a work area where work of each process is performed, and a temporary storage area where articles between the processes are temporarily stored,
The warehouse design system has a control unit and a storage unit connected to the control unit,
The storage unit,
Information indicating the amount of work in each of the steps for the article,
Information indicating a workable time zone of the plurality of processes;
Process before and after information indicating an execution order of the plurality of processes,
Layout information indicating the arrangement and area of each area,
Step use resource type information indicating the type of resource used in each step and the occupied area of the resource for each type,
Holding the packaging information indicating the occupied area of the article,
The control unit includes:
Calculating the upper limit of the resource amount in each area based on the area of each area, the margin ratio of the area of each area, and the occupied area per resource;
Based on the amount of work of each of the steps and the productivity indicating the amount of work that can be processed per unit time in each of the steps, based on the total man-hours of each of the steps, By dividing and allocating to the workable time period, a work schedule plan including information indicating a work amount for each time period of each process is generated,
Calculate the required resource amount plan to realize the work schedule plan,
When the resource amount calculated as the required resource amount plan exceeds the upper limit of the resource amount in each area, change the work schedule plan,
By calculating the required resource amount plan to realize the changed work schedule plan, all the work of the plurality of processes indicated by the information indicating the work amount is performed in the workable time zone, And, based on the process use resource type information and the layout information, create a work schedule plan and a required resource amount plan in which resources used in each process are determined to be accommodated in the work area of each process,
Based on the work schedule plan, for each time period, calculate a work end ratio indicating the ratio of completed work among all the work of each process,
The difference between the work completion ratio of the preceding process and the work completion ratio of the subsequent process is multiplied by the passing amount of the temporary storage area between the processes based on the work completion ratio of each process and the process context information for each time period. By calculating the amount of articles temporarily placed between processes for each time slot,
Based on the amount of the article temporarily placed between the processes and the packing information for each time period, calculate the required area of the temporary storage area between the processes for each time period,
If the maximum value of the required area of the temporary storage area between the processes for each time period exceeds the area of the temporary storage area based on the layout information, the articles temporarily stored between the processes are in the temporary storage area between the processes. Determined to be unacceptable,
If the article temporarily placed between the steps cannot be accommodated in the temporary placement area between the steps, a time period in which the required area of the temporary placement area between the steps exceeds the area of the temporary placement area based on the layout information In, the amount of work in the previous process of the temporary storage area is reduced, or by increasing the amount of work in the post-process of the temporary storage area, the work schedule plan and the required resource amount plan are changed,
A warehouse design system that outputs the work schedule plan and the necessary resource amount plan when articles temporarily placed between the processes can be accommodated in a temporary storage area between the processes.
(2) The warehouse design system according to (1) above,
The control unit includes:
If the work end ratio of the post-process exceeds the work end ratio of the preceding process by reducing the work amount of the previous process, the work end ratio of the post-process becomes the work end ratio of the previous process. Reduce the amount of work in the post-process so as not to exceed
If, by increasing the amount of work in the post-process, the work completion ratio of the post-process in the time zone exceeds the work completion ratio of the previous process, the work completion ratio of the post-process becomes the work completion ratio of the previous process. A warehouse design system characterized by increasing the amount of work in the preceding process so as not to exceed.
(3) The warehouse design system according to (1),
The storage unit further holds shift information indicating an operation time zone of the resource of each type of each shift,
The control unit includes:
By allocating the amount of work of each process to each time zone so that resources operating in each time zone are used, the work schedule draft is created,
Based on the work schedule plan, calculate the required area of the work area for resources used in each time slot,
If the calculated required area of the work area exceeds the area of the work area based on the layout information, it is determined that the resources used in each step cannot be accommodated in the work area of each step, Change the work schedule draft,
When the calculated required area of the work area does not exceed the area of the work area based on the layout information, it is determined that the resources used in each step can be accommodated in the work area of each step. And warehouse design system.
(4) The warehouse design system according to (3) above,
The control unit includes:
Before a work schedule plan and a required resource amount plan determined that the resources used in each process can be accommodated in the work area of each process are created, if a predetermined end condition is satisfied, Among the obtained multiple work schedules and required resource plans, the work schedule and the required resource plan with the smallest work area shortage are output, and the output work schedule and the required resource plan are supported. A warehouse design system that outputs a required area of a work area to be operated.
(5) The warehouse design system according to (4) above,
The control unit, if it is determined that a predetermined ending condition is satisfied before the article temporarily placed between the processes can be accommodated in the temporary placement area between the processes, and is obtained by then. Among the plurality of work schedule plans and the required resource amount plans, the work schedule plan and the required resource amount plan with the shortest amount of the temporary storage area are output, and further, the provisional work corresponding to the output work schedule plan and the required resource amount plan is performed. A warehouse design system that outputs the required area of the storage area.
(6) The warehouse design system according to (5) above,
The plurality of areas include a first area and a second area,
The control unit may determine that a maximum value of a total value of the required area of the first area and a required area of the second area for each time zone is the maximum value of the required area of the first area for each time zone. If the total value of the required area of the first area and the required area of the second area is smaller than the total value of the required area of the second area for each time zone, A warehouse design system for outputting as a required area when at least one of the first area and the second area is shared.
(7) The warehouse design system according to (5),
The control unit calculates a surplus amount or a shortage amount of each area based on a required area of each area and an area of each area included in the layout information, and outputs a result thereof. Warehouse design system.
(8) The warehouse design system according to (7),
An output unit that is connected to the control unit and outputs an image,
The control unit, information indicating the arrangement of the respective areas, information indicating the presence or absence of a surplus amount or a shortage amount of the respective areas, and at least a part of the surplus of the surplus area, A warehouse design system, wherein a layout diagram including information indicating a recommended replacement area to be partially replaced is output to the output unit.
(9) The warehouse design system according to (7),
The control unit includes:
If any of the plurality of areas is insufficient, change the workable time zone,
A warehouse design system, wherein when the shortage of the area is resolved based on the changed workable time zone, the changed workable time zone is output.
(10) The warehouse design system according to (1),
The storage unit further holds information indicating the productivity of the work in each of the steps, and information indicating the amount of the work target in each of the steps,
The layout information includes information indicating an arrangement of each area in the warehouse,
The control unit includes:
Based on the productivity and the amount of the work target, calculate the work amount in each of the steps,
When the operation of any of the steps includes the transfer of an article between the areas, the transfer path of the article between the areas is predicted based on the layout information, and the predicted transfer path and a predetermined transfer speed are set. A warehouse design system that calculates a transfer time between the areas based on the transfer time, and calculates an amount of work in each of the processes based on the productivity calculated based on the transfer time.
(11) The warehouse design system according to (10),
The control unit, when at least one of the area of each area in the warehouse or the layout of each area included in the layout information is changed, based on the changed layout information of the article between the areas Predicting a transport route, calculating a transport time between the areas based on the predicted transport route and a predetermined transport speed, and performing an operation in each of the processes based on the productivity calculated based on the transport time. Change the amount,
Based on the changed amount of work, all the work in the plurality of processes is performed in the workable time zone, and is used in each of the processes based on the process use resource type information and the layout information. Create a work schedule plan and a required resource plan where resources are determined to be accommodated in the work area of each process,
Determining whether or not articles temporarily placed between the processes can be accommodated in a temporary storage area between the processes based on the work schedule plan, the process context information, the package information, and the layout information. Warehouse design system.
(12) The warehouse design system according to (1),
The storage unit,
Shift information indicating an operation time zone of the resource for each type of shift;
Resource cost information indicating a unit cost of the resource corresponding to a combination of the type of the resource and the shift of the resource, and further holds,
The control unit includes:
Create a plurality of candidates for the work schedule plan including information indicating the amount of work for each time period of each process,
The required resource amount corresponding to each candidate of the work schedule plan, by allocating resources of the type used in each of the steps and shifting resources having the lowest cost unit price that are operating in each of the time zones. Create a proposal,
Among the plurality of candidates for the work schedule plan and the required resource amount plan, a candidate having a minimum total cost calculated based on the resource cost information is created as the work schedule plan and the required resource amount plan. Warehouse design system.
(13) The warehouse design system according to (12),
The storage unit further holds area information indicating a unit price of each area,
The control unit determines the resource cost information, the area information and the total cost calculated based on the calculated required area among the plurality of candidates, the work schedule plan and the required resource amount. A warehouse design system that is created as a plan.

  Note that the present invention is not limited to the above-described embodiments, and includes various modifications. For example, the above-described embodiments have been described in detail in order to explain the present invention in an easy-to-understand manner, and are not necessarily limited to those having all the configurations described above.

  The above-described respective configurations, functions, processing units, processing means, and the like may be partially or entirely realized by hardware, for example, by designing an integrated circuit. In addition, the above-described configurations, functions, and the like may be implemented by software by a processor interpreting and executing a program that implements each function. Information such as a program, a table, and a file for realizing each function is stored in a memory, a hard disk drive, a storage device such as an SSD (Solid State Drive), or computer-readable non-temporary data such as an IC card, an SD card, and a DVD. It can be stored in a storage medium.

  Also, the drawings show control lines and information lines considered necessary for explaining the embodiment, and do not necessarily show all control lines and information lines included in an actual product to which the present invention is applied. Not necessarily. In fact, almost all components may be considered to be interconnected.

Claims (3)

A warehouse design system for designing a warehouse to be carried out after performing a plurality of processes on the goods carried in,
The warehouse has a plurality of areas including a work area where work of each process is performed, and a temporary storage area where articles between the processes are temporarily stored,
The warehouse design system has a control unit and a storage unit connected to the control unit,
The storage unit,
Information indicating the amount of work in each of the steps for the article,
Productivity indicating the amount of work objects that can be processed per unit time in each of the steps,
Information indicating a workable time zone of the plurality of processes;
Process before and after information indicating an execution order of the plurality of processes,
Information indicating the amount of passing objects in the temporary storage area between processes,
Layout information indicating the arrangement and area of each area,
Information indicating a margin rate of the area of each area,
Step use resource type information indicating the type of resource used in each step and the occupied area of the resource for each type,
Shift information indicating an operation time zone of the resource for each type of shift;
Holding the packaging information indicating the occupied area of the article,
The control unit includes:
Calculating the upper limit of the resource amount in each area based on the area of each area, the margin ratio of the area of each area, and the occupied area per resource;
The work amount of each of the steps, the productivity indicating the amount of work targets that can be processed per unit time in each of the steps, the information indicating the workable time zones of the plurality of steps, and the shift information, Calculate the total man-hours of each process, and divide and assign the total man-hours of each process to the workable time zone, so that all work of all processes is performed in the workable time zone, and Generate a work schedule plan including information indicating the amount of work for each time zone of each process, so that the type and the resources of the shift operating during the time zone are used,
Based on the work schedule plan, for each time period, calculate a work end ratio indicating the ratio of completed work among all the work of each process,
The difference between the work completion ratio of the preceding process and the work completion ratio of the subsequent process is multiplied by the passing amount of the temporary storage area between the processes based on the work completion ratio of each process and the process context information for each time period. By calculating the amount of articles temporarily placed between processes for each time slot,
Based on the amount of the article temporarily placed between the processes and the packing information for each time period, calculate the required area of the temporary storage area between the processes for each time period,
A warehouse design system, wherein a surplus amount or a shortage amount of each area is calculated based on a required area of each area and an area of each area included in the layout information, and a result is output. The warehouse design system according to claim 1,
An output unit that is connected to the control unit and outputs an image,
The control unit, the information indicating the arrangement of the respective areas, the information indicating the presence or absence of the surplus amount or the shortage amount of each area, and at least a part of the surplus of the surplus area, A warehouse design system, wherein a layout diagram including information indicating a recommended replacement area to be partially replaced is output to the output unit. The warehouse design system according to claim 1,
The control unit includes:
If any of the plurality of areas is insufficient, change the workable time zone,
A warehouse design system, wherein when the shortage of the area is resolved based on the changed workable time zone, the changed workable time zone is output.