JPH04134559A - Raw material ordering system - Google Patents

Abstract

PURPOSE:To efficiently order raw materials by deciding the amount of materials to be ordered based on the required amount of the raw materials to be set with the daily change of a production plan and automatically updating the amount of stocked raw materials and the production plan when receiving the stock information of the raw materials and the production result information. CONSTITUTION:An order amount deciding means A is provided to decide the amount of the raw materials to be ordered according to the attribute of the raw materials, the amount of stocked raw materials, the remaining amount of the order, the amount in the middle of ordering and the required amount of the raw materials while successively setting or changing the daily required amount of the raw materials with the daily set or change of the production plan when ordering the raw materials after deciding the amount of the raw materials to be ordered based on the production plan of a product. On the other hand, a data input processing means B is provided to change the amount of the stocked raw materials by receiving the stock information of the raw materials and to change the production plan and the amount of the stocked raw materials by receiving the production result information. Thus, the raw materials can be efficiently managed and supplied without wasting them.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a raw material ordering system that allows for flexible ordering of raw materials and materials required for product production without waste.

[Conventional technology]

Conventionally, the method of ordering raw materials has been the most commonly adopted fixed-point fixed-quantity ordering method, although the method differs depending on the type of industry.

This fixed-point fixed-quantity ordering method is a method in which the safety stock amount for each raw material is determined in advance as a fixed point, and an ordering instruction is issued when the number of raw materials decreases and reaches the fixed point. This method was based on the idea of keeping a stock of raw materials that were considered to be safe, and was a simple and optimal method for industries that could always maintain stable production.

[Invention or problem to be solved]

However, the above-mentioned fixed-point fixed-quantity ordering method is not preferable in high-mix, low-volume production, especially when dealing with products that are highly dependent on raw materials or product production volumes, because losses become too large. In other words, when a large number of common raw materials exist in a large number of products, and a large number of products are produced by changing the combination of these raw materials, the fixed-point quantitative ordering method is preferably used. two products A, B,
If C has common raw material a, the safety stock amount of raw material a, that is, the fixed point, is set by taking the maximum value when producing the above three products, so it is inevitable that the safety of the raw material The amount of inventory becomes large, and as a result, an excessive amount of raw material inventory is held.

Therefore, recently, MRP (Material Req.
A raw materials ordering method called uirements plan has been adopted. This is a method of ordering only the required quantity of raw materials for each production quantity of each product, and is intended to prevent unnecessary stock of raw materials.

However, in this method, all the raw materials for each product are arranged in a packaged form, so while it is convenient, there is a problem that it is difficult to make maneuvers. In other words, raw material a for product A is strictly for product A, and even if raw material a is required due to production instructions for product B, raw material a for the above product is Instead of diversion, they have no choice but to wait for the arrival of raw material a for product B before starting production. This is because raw materials a, b, c, etc. of product A are packaged in the necessary quantities in order to minimize raw material loss, so if raw material a is repurposed as described above,
This is because other raw materials corresponding to this diverted quantity are wasted.

The present invention has been developed in view of the above-mentioned circumstances, and is capable of supporting a flexible, ready-to-run production system without having an excessive inventory of raw materials, and is particularly useful in high-mix, low-volume production, where complicated raw material management and management are required. The purpose is to provide a raw material ordering system that can efficiently supply supplies without waste.

[Means to solve the problem]

In order to achieve the above object, the raw material ordering system of the present invention has the following configuration. In other words, it is a system that determines the order amount of raw materials based on the product production plan and places the order.As the daily production plan is set or changed, the daily raw material requirement is sequentially set or changed, and the raw material attributes are also changed.

an order amount determining means for determining the order amount from the amount of raw materials in stock 2, the amount of remaining orders 2, the amount of orders in progress, and the above-mentioned required amount of raw materials; The gist of the present invention is to include a data input processing means for changing the production plan and raw material inventory amount by receiving the data.

Further, in the data input processing means, the remaining order amount is changed by receiving the raw material order confirmation information and inventory information, and the order amount is changed by receiving the order confirmation information. is preferred.

[Effect]

According to the above configuration, the required amount of each raw material is set based on the daily production plan, and the required amount is changed each time the production plan is changed.

And the standard lead time and supply amount of raw materials.

Raw material attributes such as safety stock amount, raw material inventory amount 9 Order backlog amount 9
By determining the order amount based on the amount to be ordered and the required amount of raw materials and placing an order, you can avoid unnecessary orders (you can have the necessary raw materials on hand in the amount you need when you need them). It looks like this.

In addition, by receiving raw material inventory information and production performance information, the production plan and raw material inventory are automatically updated, making it possible to order flexible raw materials that always correspond to the movement of raw materials.

〔Example〕

Embodiments of the present invention will be described below based on the drawings.

FIG. 1 is an overall configuration diagram showing an embodiment of a raw material ordering system according to the present invention. As shown in the figure, this system includes order quantity determining means (A) and data input processing means (B).
), and an order quantity determining means (A)
is an initial setting section (1), a production plan setting section (2), a required quantity setting section (3), a production plan changing section (4), a required quantity changing section (5), and an order quantity determining section. (6).

The initial setting section (1) includes the inventory data table (7) shown in Figure 2 and the production plan data table (8) shown in Figure 3.
, Production plan change delivery data table (9) shown in Figure 4
, and the required quantity data table (10) shown in Fig. 5 are connected, and each of these data tables (7), (
8), (9), and (10) are initialized by the steps shown in the flowchart of FIG. That is, the inventory data table (7) shown in Fig. 2 stores inventory amount data for each raw material, and the production plan data table (8) shown in Fig. 3 stores daily production plan data or data for each product. Stored. In addition, the production plan change delivery data table (9) shown in FIG. 4 is used when changing the data in the requirements data table (lO) shown in FIG. There is a device that transfers data between the two, and its details will be explained later.

The required amount data table (10) stores required amount data for each raw material on a daily basis.

Therefore, Step ■: Receives the input of the current actual inventory amount W of raw material R1, Step ■: Replaces the inventory amount data Z1 of Ri stored in the inventory data table (7) with W and creates a new Zi shall be. Then, Step ■: Check whether the above process has been completed for all raw materials, and if it has been completed, Step ■: Set all the production plan data Xij stored in the production plan data table (8) to 0. At the same time, Step O: Set all delivery data ΔXij stored in the production plan change delivery data table (9) to 0, and further, Step ■: Requirement data Y1j stored in the requirements data table (10) Set all to 0 and complete the initial settings.

In other words, the actual inventory amount at the current time does not necessarily match the original inventory amount data simply subtracting the usage amount, and there may be slight errors due to damage, etc., so first, at the start of all processing, It is necessary to correct the inventory data. Also, production planning, production plan change delivery.

And for each data of the required amount, everything is re-partitioned and started from 0.

After making the initial settings in this way, the production planning setting department (
In 2), the production plan is set again.

The production plan setting section (2) is connected to the production plan data table (8) mentioned above, and the production plan is set as shown in the flowchart shown in FIG. That is, Step ■: Receives the input of production plan amount X of product Pi on day d, Step ■: Replaces the production plan data that is O due to the above initial setting with X and makes it a new Xid, Step ■, All The process of setting the production plan is completed after checking whether the production plan has been set for the product.

Thereafter, the required amount setting section (3) calculates the required amount of raw material diagonal reinforcement at an initial stage. This required amount setting section (3)
The production planning data table (8), the required quantity data table (lO), and the product composition data table (11) are connected to the above, and the initial required quantity is calculated by the steps shown in the flowchart of Fig. 8. It is supposed to be done. In this product configuration data table (11), the 9th
As shown in the figure, data on the amount of each raw material required to produce one unit of each product is stored.

Therefore, step ■: From the production planning data table (8),
Take out the planned production quantity Xjd of i on day d, and step ■: From the product composition data table (11), obtain the required quantity of raw materials Ci+, Ci□,
..., take out Cin, step ■; this C1j(j
=1.2. ..., n) and the above Xid as Yjd (j=L2...
, n). Then, step ①: Check whether all of the above processes have been completed and complete the setting of the required amount.

The flow from the initial setting to the setting of the required quantity has been described above. Next, the flow when changing the required quantity data in conjunction with a change in the production plan data will be explained.

The production plan data is changed in the production plan change section (4) as shown in the steps of the flowchart shown in FIG. In addition to the production plan data table (8), the production plan change delivery data table (9) shown in FIG. 4 is connected to the production plan change section (4). Therefore, Step ■: Upon receiving the input of the production plan amount X of the product Pi on the d day, Step ■: Retrieve the production plan data Xid of the product Pi on the d day stored in the production plan data table (8), Step (2) The difference between X and Xid is set as ΔX. Step (2): The value of Xid is replaced with X and a new Xid is set.

After that, step ■: Production plan change amount ΔXi for product Pi on day d stored in the production plan change delivery data table (9)
Step 2: Add the above ΔX to this ΔXid to create a new ΔXid. Step 2: Finish changing the production plan data after confirming that there are no other changes to the production plan data.

When the production plan data is changed in this way, the required amount changing section (5) automatically changes the required amount data accordingly. In this required amount change section (5),
Production plan change delivery data table (9), product composition data table (11), and requirements data table (lO
) are connected, and the required amount data is changed by the steps shown in the flowchart of FIG. That is, Step ■: Extract the production plan change amount ΔXid of the product Pi on day d from the production plan change delivery data table, Step ■: Find the raw materials required to produce one unit of the product Pi from the product composition data table (11). Required amount of C
While taking out i+, Ci2,..., Cin, Step 0: Take out the required quantities Y, d, Y, d,..., Ynd of each raw material on day d from the required quantity data table (lO). Then, Step ■: Yjd (j=1.2...,n) above
, Ci j (j = 1.2.-, n) and ΔX
id and new Yjd, and step 0: ΔXid in the production plan change delivery data table (9) is set to 0. Then, Step (2): Check whether all of the above-mentioned change processes have been completed, and finish changing the required amount.

That is, when a change occurs in the production plan, the change is made in the requirements data table (lO) from the production plan data table (8) through the production plan change delivery data table (9). Even if changes in production plans for the same product occur consecutively, it is possible to immediately respond and change the required quantity.

After setting and changing the daily raw material requirements as described above, the order amount determining section (6) calculates the order amount.

This order quantity determination section (6) includes an inventory data table (7).
), and the requirements data table (10), the raw material attribute data table (12), the order data table (13), and the backlog data table (14) are connected, and the flowchart in Figure 12 The order quantity is calculated by the steps shown.

FIG. 13 shows an example of the raw material attribute data table (12). This data table (
12) stores the name of the ordering manufacturer, standard lead time, daily supply amount, and safety stock amount for each raw material as attribute data for each raw material. In addition, the on-order data table (13) shown in FIG. 14 and the back-order data table (14) shown in FIG. .

However, Step ■: From the raw material attribute data table (12),
Standard lead time Ti of raw material Ri, daily supply amount Q1
．． and the safety stock amount Si, and in step (2), add the above standard delivery time Ti to the current relative date d and set it as the designated delivery date T0. Therefore, at the time of initial setting, the standard lead time or the designated delivery date will be used as is. Then, Step ■: Take out the inventory quantity Zi of raw material Ri from the inventory data table (7), and further, in Step σ, extract the daily required quantity of raw material Ri Yi+, Yi2. -, Yir are taken out; Step ■; the above Yi, , Yi2. =·,Yi r is copied as Y, ,Y, ,...,Yr''.

Using the values from step 01 and above, the following inequality (1), (
2) Find k that satisfies all of the following (k=T”T”+
1. ..., r), Step ■: Set the minimum k among the k found as K,
The value of Yk'' is changed using the following equation (3).

Yk" = Yk" 10S i...(3
) Step 22 Next, find 1 and 2 that satisfy the inequality (4) below (k + = L 2.-, r, k2
= r, -, 1 +1. 1 + 2), k step ■: Using the obtained 1 and 2, the following formula (5
) to calculate D.

K.

... (5) Step 0. Here, if D<Yv+", add 1 to k and return to step (2) above; if D≧Yk, next (i
) and (ii).

(i) Yk+°-D (ii) Y j” -Q i (J = + +1. = 2 + 2...., = 2) Step 0; Then, check whether kl or r has been reached. , if not reached, replace 1 with 2, return to step (2), and repeat the steps up to this point.

As soon as kl or r is reached, all changes to the required quantity data are completed, and the required quantity data table (10) is completed.

Before proceeding to the next step, we will explain the above process in an easy-to-understand manner by citing specific numerical values.

Step (2): Now assume that in the raw material attribute data table (12), each data regarding raw material R is as follows.

Standard lead time T1-4 days Daily supply amount Q, = 8 pieces Safety stock amount 51-2 pieces Step ■, designated delivery date T”=T,=4.

In step (2), it is assumed that the inventory amount Z of raw material R1 is 23 pieces in the inventory data table (7).

Step (2): Take out the daily required amount of raw material R1 at the present time from the required amount data table (10) as shown in the table below.

Step ■; Y, =5. Y2=8. Y36,・
..., Y+o=6.

Step ■: To=T”, T”+1. ..., 10,
That is, k=4.5. ..., when calculating among 10,
When k=4, the prescribed inequalities are not satisfied, but when k=5, Step ■: is satisfied, and all the inequalities are satisfied.

In step ■;, = 5, y, " = Ys " 10S
, =4+2=6, therefore, the current value of Y, =4 is changed to Ys ``''6.

Step ■: Find that 1 and 2 satisfy k,=a, and 2=4.

becomes.

Step (1, D=8≧Y k r°=6, so (i
)Ys”=8 (n)Ya”=8.

That is, Ys'' = 6. Y4 = 10 are changed to 8, respectively.

In step (2), = 3, and r = 10 has not been reached, so k1 = 4, and the process returns to step (2) and repeats the steps up to this point.

Then, in addition to + =6. kt = 7 is found, and as a result, in step [F], the following changes are made: (i) Y s = 8 (ii) Y, = 8.

Therefore, the required quantity data table (10) after the change becomes as shown in the table below.

There is. Then, Step 0: From the backlog data table (14), calculate the daily backlog of raw materials Ri gl+, gt,..., gir
Step 0: Calculate the following equation (6).

If you compare this with the one before the change, you can see that the required quantities of 10 pieces on the 4th day and 9 pieces on the 7th day have been brought forward to the 3rd and 6th day, respectively, and this raw material R1 The data is adapted to the daily supply amount.

Below, return to the flowchart in Figure 12 again and step @
The following flow will be explained.

Step ■; From the on-order data table (13), the daily on-order amount of raw material R1 ft,, fL+...f
Take out the ir.

In this in-order data table (13), it is stored as the order amount, the amount of items that have not yet been added to the inventory quantity Zi, or the in-order amount... (6) Step @; Calculated F>O and a purchase order is created, and the fij is set to 0. At this time, the order of target fij is the one close to j or r,
That is, from the back.

Step @: Calculate the formula (7) below, ... (7) If F9>0, print a purchase order with the order quantity as Fl, calculate fiT" + F" and create a new fiT"
shall be. Then, Step 0: Confirm that all the raw materials have been processed as described above, and the process ends.

Below, the flow from step ■ onward is as described in step 0.
This will be explained in detail as a sequel.

Steps (2) and (o): Extract the daily on-order amount and daily back-order amount of raw materials RI from the on-order data table (13) and the back-order data table (14) as shown in the table below. The top row of the table below shows the raw material R1 obtained up to step 0.
It shows the daily requirement of.

Step 0: Here, compute
That is, it is changed to 0 in order starting from the 10th day. Suppose the result is as shown in the table below.

Step [phase]:=1, and since F''>o, print the purchase order with the order quantity as 1, and print a new f14 with 1.

When the order amount is determined by the order amount determining means (A) as described above, a purchase order is issued and the data is sequentially processed by the data input processing means (B). This data input processing means (B) includes an order confirmation data input processing section (15), a raw material warehousing data input processing section (16),
It is composed of a production performance data input processing section (17).

The order acknowledgment data input processing section (15) has the aforementioned backorder data table (14) and order progress data table (
13) is connected, and data processing is performed according to the steps shown in the flowchart of FIG.

That is, Step ■: Receive data on the order quantity and scheduled delivery date d of raw materials Ri from the order acknowledgment from the raw material supplier, Step ■: Receive the order amount gid of raw materials R10d on the day d in the backlog data table (14) Step ■: Add the order amount gid to the above order quantity gid to create a new gid, and further, Step ■: The unordered amount of raw material Ri in the on-order data table (13) ft++ ftt+ ... fi
Take out r.

Step ■: Search for k that satisfies the inequality (8) below, where fto=0), Step ■-1: If it exists, (i) fl++fi2.extracted in step ■.・
..., set fir to 0 and create a new fik, Step ■-2: If it does not exist, set the remaining order amount gi
d is returned to its original state and treated as an error in the input data. Then, step ■: It is checked whether there is any other order confirmation data, and the order confirmation data input process is completed.

In addition, the above-mentioned inventory data table (7) and backorder data table (14) are connected to the raw material receipt data input processing unit (16), and data processing is performed according to the steps shown in the flowchart of FIG. It has become.

That is, Step ■; Upon receiving the input of the stocking quantity U of raw materials Ri, Step ■; Raw materials Ri in the inventory data table (7)
Take out the inventory quantity Zi; Step ■: Add the stocking quantity U to the above inventory quantity Zi to make it a new Zi; Step ■; Inventory quantity gin, gi2. ”・Take out the gir.

Step ■: Find k that satisfies the inequality (9) below, where gio = 0), Step ■-1: If it exists, (i) gi + gin, ..., set gi (k-1) to 0 At the same time, create a new gik, and step ■-2; If it does not exist, change the inventory amount Zi
is returned to its original state and treated as an error in the input data.

Then, Step 0: Check whether there is any other raw material warehousing data, and end the raw material warehousing data input process.

In the production performance data input processing section (17), the production plan data table (8) connected to the section
, production plan change delivery data table (9), inventory data table (7), and product composition data table (11)
Based on each data, input processing of production performance data is performed through the steps shown in the flowchart of FIG.

That is, Step ■; Upon receiving the input of the production results V of product Pi, Step ■; From the production planning data table (8),
Take out the production plan data X 11 + X 121

Step ■; Step ■; Take out the daily increase/decrease value ΔX i+ * ΔXir, calculate ΔX1j−Xij, and let this be j=1.2. ..., -1), and Xij is set to 0. Then, ΔXik is newly set, and step 2 is set to =V.

Step ■: Find k that satisfies the inequality (lO) below (X1o=0).

Step ■: Set the production plan change delivery data table Xik.

Step 0: Get the inventory amount Zi of product Pi from the inventory data table (7), Step 0: Get the required amount Ci+ + of raw materials Ri needed to produce one unit of product Pi from the product composition data table (11). Take out Ci2+ -=+ Cin, Step ■; Calculate usage amount C1jXV of raw material Rj (j=1.2...,n), subtract that value and newly calculate Zj
shall be. Then, Step 0: Check whether there is any other production record input data, and then complete the production record data input process.

As described above, in the data input processing means (B), each data is automatically updated based on the sequentially sent order confirmation data, raw material warehousing data, and production performance data. Therefore, the inventory data table (
7), the data in each data table such as the production planning data table (8) and the requirements data table (10) are always flexible enough to respond to changes in the movement of raw materials, etc., which prevents unnecessary orders. Things like being fulfilled are eliminated.

In addition, since it is possible to reliably order the required quantity of each raw material on a daily basis, the problem of production delays due to raw material delays is resolved.

〔Effect of the invention〕

As described above, according to the raw material ordering system of the present invention, it is possible to order raw materials that accurately correspond to daily production plans. In other words, the required amount of raw materials is set according to changes in the daily production plan, and based on the set raw material required amount, the order amount is calculated from this, raw material attributes, raw material inventory amount, 2 backlogs, 2 pending orders. By making decisions, you can ensure that you have the raw materials you need when you need them.

When raw material inventory information and production performance information is received, the raw material inventory amount and production plan are automatically updated, so the order amount can be determined without any waste, and the raw material inventory can be reduced. This makes it possible to immediately respond to a production system without overloading, and makes it possible to efficiently order raw materials, which can be complicated, especially in high-mix, low-volume production, without waste.

[Brief explanation of the drawing]

Fig. 1 is an overall configuration diagram showing an embodiment of the raw material ordering system of the present invention, and Figs. 2 to 5 show an inventory data table, a production plan data table, a production plan change delivery data table, and a requirements data table, respectively. 6 is a flowchart showing the steps in the initial setting section, FIG. 7 is a flowchart showing the steps in the production plan setting section, FIG. 8 is a flowchart showing the steps in the required quantity setting section, and FIG. 9 is a flowchart showing the steps in the production plan setting section. FIG. 10 is a flowchart showing the steps in the production plan changing section; FIG. 11 is a flowchart showing the steps in the required quantity changing section; FIG. 12 is a flowchart showing the steps in the order quantity determining section; Figures 13 to 15 are a raw material attribute data table and an ordering data table, respectively. FIG. 16 is a flowchart showing the steps in the order acknowledgment data input processing section, FIG. 17 is a flowchart showing the steps in the raw material warehousing data input processing section, and FIG. 18 is the production results. 3 is a flowchart showing steps in a data input processing section. (1)...Initial setting section, (2)...Production plan setting section (3)...Required amount setting section, (4)...Production plan changing section (5)...Required amount changing section (6)...Order quantity determination unit (15)...Order confirmation data input processing unit (16)
)...Raw material warehousing data input processing unit (17)...Production performance data input processing unit (A)...Order quantity determination means (B)...Data input processing means Inventory data table Production plan change delivery data Table Production Planning Data Table Requirements Data Table Figure 6 Figure Figure

Claims (1)

[Claims] 1) A system that determines and orders the amount of raw materials to be ordered based on a product production plan, which sequentially sets or changes the required amount of raw materials for each day as the daily production plan is set or changed. In addition, raw material attributes,
An order amount determination means that determines the order amount from the raw material inventory amount, the remaining order amount, the unordered amount, and the above-mentioned raw material requirement amount, and the above-mentioned raw material inventory amount by receiving the raw material inventory information, and the production performance information. A raw material ordering system comprising: data input processing means for changing the production plan and raw material inventory amount by receiving data. 2) In the data input processing means, the remaining order quantity is changed by receiving order confirmation information and inventory information for raw materials, and the pending order quantity is changed by receiving the order confirmation information. raw material ordering system.