JPH06156650A - Distribution simulation method in physical distribution center management system - Google Patents

Abstract

PURPOSE:To simulate planned delivery so as to enable the early detection of under-and-over delivery of parts and products. CONSTITUTION:In a physical distribution center management system formed also of a central control unit provided with terminals for managing the warehousing-delivery and storage of parts and controlling an automated warehouse receives a delivery list on the delivery predetermined parts from a host computer to prepare a delivery list master, and edits and the like on the basis of this delivery list master to prepare a distribution simulation master. From this distribution master, distribution simulation of distribution assuming delivery without actually delivering parts is performed, and plural parts are put in one lot for the same time delivery according to the data of the distribution simulation master and actually delivered as planned.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a distribution simulation method for a distribution center management system. More specifically, it relates to a distribution simulation method of a distribution center management system, which can simulate the distribution of parts on the assumption that they have been delivered from a distribution center, that is, a warehouse without actually leaving.

[0002]

2. Description of the Related Art Various automatic warehouse systems are known for inventory management of factory parts. From the perspective of factory management, it is better to keep parts and products in stock as little as possible. However, if the management is improper and too small, the factory line may stop due to lack of parts and materials.

On the other hand, there are various types, sizes, and weights of parts (sometimes assembled products) produced in factories, which are not uniform. For example, as in a machine tool manufacturing plant, a bed that is a large casting part, a cover that is a sheet metal material, a spindle, a feed screw shaft, a hydraulic component that is a small part,
The types, sizes and weights of electrical components, bolts, nuts, etc. are not uniform.

In the case of parts / products assembled or produced in lot units, it is necessary to collectively bring out a plurality of parts / products at the same time in a planned manner, that is, to carry out so-called planned shipping. It is not easy to supply these multiple parts and products to the production line without excess or deficiency and to operate the factory efficiently with the minimum inventory. For this reason, for example, the Kanban system has emerged and has achieved certain results.

However, in recent years, these systems have also been called for reforms because they are said to be a cause of labor shortage and traffic congestion in the parts industry, the logistics industry and the like. In recent years, there has been a demand for an inventory management system that does not run out of stock and does not run out of stock.

[0006]

The present invention has been invented in the above technical background, and achieves the following objects.

It is an object of the present invention to provide a distribution simulation method for a distribution center management system, which has a function of simulating planned shipping and detecting excess or deficiency of parts / products at an early stage.

[0008]

In order to achieve the above-mentioned object, the present invention adopts the following means and operations.

In a distribution center management system consisting of a central control unit equipped with terminals for managing parts entry / exit / storage and controlling an automatic warehouse, the above-mentioned parts that are scheduled to be shipped are received from a host computer by a shipping list. Assuming that a shipping list master is created from the shipping list, editing simulation is performed based on this shipping list master to create a serving simulation master, and the parts are shipped from the serving simulation master without actually shipping. The distribution center management system is operated to perform a serving simulation.

It is preferable that a plurality of parts are put together at the same time and actually planned to be delivered using the data of the serving simulation master.

[0011]

Embodiments of the present invention will be described below with reference to the drawings. 1, 2, and 3 are diagrams showing an outline of a distribution center having two floors, one above the other. 1 is a plan view of the first floor, FIG. 2 is a plan view of the second floor, and FIG. 3 is a side view of FIGS.

Flat warehouses 1a, 1b A flat warehouse 1a and a carry-in passage 2 are arranged on the floor of the first floor. The flat warehouse 1a is a warehouse for storing relatively large materials such as beds of machine tools and headstocks, work-in-progress, and products. Similarly, a flat warehouse 1b is placed on the floor of the second floor for flatly placing the product. The carry-in / carry-out path 2 is a carry-in / carry-out path for carrying in materials and products that are stored and managed in a warehouse. The flat warehouses 1a and 1b are preliminarily divided in a plane, and the large materials, work-in-process, products, etc. are arranged in a plane in the division and stored.

Rotor stocker storage device 9 Small parts such as predetermined small parts such as bolts, nuts, clips, and bearings are the second floor stocker 9a.
It is stored in. This stocker 9a is stored in the vertical rotary type rotorist stocker storage device 9 in units of stocker 9a. Therefore, the extremely small parts are not managed in units of one, but are managed in units of the stocker 9a. Also,
The information on entry and exit from the stocker 9a is input from a terminal (not shown) dedicated to the rotor stocker by the barcode printed on the exit list.

Small automatic warehouse 3 Parts other than the large ones are first placed on the receiving station 5 for receiving on the first floor, and then carried into the automatic small warehouse 3. The small article automatic warehouse 3 is an automatic warehouse having three-dimensional shelves, and has a stacker-crane type carrier truck that moves between shelves.

In this embodiment, the stacker crane 6 comprises three units. The small article automatic warehouse 3 is composed of shelves 3a to 3f for storing six rows of small parts, and a plurality of bucket shelves 4 spatially partitioned in a matrix are arranged on the shelves 3a to 3f. The small parts stored in the small automatic warehouse 3 are put in buckets for different parts and stored in the shelves 4.

Since the small automatic warehouse 3 is equipped with two vertical conveyors 12 and 24, the bucket 10 has one
You can carry in and out not only from the first floor but also on the second floor. Also, each shelf 3
The loading and unloading of the bucket 10 to and from a to 3f is performed by the electric carriage 35.

Large Automatic Warehouse 30 The large automatic warehouse 30 stores relatively large items mounted on the pallet P, and has two rows of shelves 30a and 30b. What is going to be loaded and unloaded from the large automatic warehouse 30 is the loading / unloading station 3 on the first floor.
1 (see FIG. 1). Loading / unloading station 31
The pallet P mounted on the
a, 32b.

However, the pallet P may be directly mounted on the loading / unloading stations 32a and 32b from the outside. Since the large automatic warehouse 30 includes the vertical conveyors 39a and 39b from the first floor and the second floor, the pallet P can be carried in and out. It can also be transferred to the exit station 40 on the second floor (see FIG. 2). From this loading / unloading station 40, it is carried out from the second floor of the distribution center to an externally connected factory.

The midsole automated warehouse 50 midsole automated warehouse 50 is for accommodating the comparison hits product components mounted on the pallet P (or bucket),
Four rows of shelves 50a, 50b, 50c, 50d are arranged. Those trying to enter and leave the automated warehouse 50
First, loading / unloading stations 51a, 5 provided on the first floor
1b (see FIG. 1). Loading / unloading station 5
The pallet P loaded on the la 1a, 51b is transferred to any of the carry-in / out stations 52a, 52b, 52c, 52d (see FIG. 1).

After that, it is mounted on one of the two electric carriages 55a and 55b and transferred to the required shelves 50a to 50d. The automatic warehouse for medium-sized goods 50 has four vertical conveyors 5
Since 9a to 59d are provided, the pallet P can be carried in and out from both the first floor and the second floor.

Automatic Sheet Metal Warehouse 70 The automatic sheet metal warehouse 70 stores skid, that is, sheet metal parts mounted on a table for transportation by a forklift. The automatic sheet metal warehouse 70 has two rows of shelves 70a, 7a.
0b is arranged. When entering or exiting the automatic sheet metal warehouse 70, a skid is first installed in the carry-in / out station 71 provided on the first floor. The skid mounted on the carry-in / carry-out station 71 is
Transferred to a. Skid is loading / unloading station 72a
Mounted on the electric carriage 75. Sheet metal automatic warehouse 70,
You cannot carry in and out from the 2nd floor.

Distribution Center Management Information System 100 FIG. 4 is a flow chart showing an outline of the information flow of the distribution center management information system of the machine tool production factory. Each system described below means a system including software and hardware. The production planning system 101 is a centralized system for planning production of products whose orders have been decided by customers and for which design has been completed, taking into consideration the capacity of equipment. The information from this production planning system 101 is first transferred to the production management system 102.

The production management system 102 is for managing the entire factory such as acceptance of machining of parts of each machine tool, progress of machining, inspection and inspection. Production management system 10
2 has three files as a lower system. The information can be input / output to / from the production management system 102 from terminals 103 installed at various places in the distribution center (see FIGS. 1 and 2). The main material inventory system 104 is a system for managing the inventory of relatively large materials such as beds of machine tools, which are castings, and headstocks.

The parts work system 105 is a system for grasping the situation of the subcontractor and the purchaser of parts processing. That is, it is a system for grasping the status such as the outsourced parts, the requestee name of the purchased parts, and the delivery date online. In the lower system of the parts work system 105,
There is a processing progress management system 106 for monitoring the progress of processing of parts in a factory. Processing progress management system 106
Is for managing the progress of processing of parts by in-house equipment.

The processing progress management system 106 can input information such as stocking of materials, stocking of parts, process movement, etc., from a terminal 107 that is appropriately placed mainly in a factory and a distribution center (see FIG. 1). In the parts work system 105,
Further, information on purchases and subcontractors by off-run is periodically input to the floppy disk 109.

The parts inventory system 110 is a system for managing the inventory of the products, semi-finished products and materials of the above-mentioned warehouses and subcontractors. For this inventory management, the parts inventory system 110 is a system including an inventory master and the like.

The purchasing / outsourcing system 108 is a system for managing the situation when ordering parts to the outside. In this embodiment, these data are input to the floppy disk 109 and this data is input to the parts work file 1.
Enter in 05. However, this data transfer may be online.

A parts inventory management system 111 is connected to a lower system of the parts inventory system 110. The parts inventory management system 111 includes the above-mentioned flat warehouse 1a,
1b and storage in and out of each automated warehouse 3, 30, 50, 70,
This is a management system for managing food distribution and inventory. The parts inventory management system 111 is the loading / unloading system 1
12, a catering simulation system 113, an inventory system 114, and the like. The loading / unloading system 112 is
Total number of pallets, buckets or skids in each warehouse,
It is a system for managing the remaining number, position, etc.

The catering simulation system 113 is
In order to complete the planned warehousing, it has a serving simulation function. It is a system for early detection of products and missing parts required for products scheduled to be shipped in a few weeks, that is, missing parts and materials. However, the actual shipping operation and the update of the inventory data in the memory are not performed. With this function, first, a delivery list master is created. A catering simulation master is created by referring to this shipping list. A simulation start instruction is given to this serving simulation master.

The inventory system 114 has a stock quantity for each item,
It is for managing the amount of inventory, the position of shelves in the warehouse, and so on. The simple I / O 115 is an input / output system for inputting parts existing in an external cooperation factory or the like. Less than,
The serving simulation function will be described.

[0031]Serving simulation system 113  This function is a function that can be operated from the terminal 116. Distribution
The Zen simulation function is actually used to
-I do not actually leave from the warehouse, but as if I was serving
The motion is modeled using a computer
It is something to do. In this example, a group of items is
Simulate batch issues, that is, planned issues
It is a function to detect missing items at an early stage. Fruit
At the time of shipping, do not update the inventory data in the memory.
Yes.

FIG. 5 is a flow chart showing a schematic flow when a part / product is delivered. It is a planned shipping, that is, a food distribution simulation is performed in advance, and immediately issues a shipping operation to each warehouse at the shipping time. If it is an issue of an individual item, issue is performed for each individual item. If you're going to arrange the catering from now on, the higher computer, that is,
Request the shipping list from the production planning system 101.

This shipping list is the production planning system 101.
Then, the serving simulation is started as described below. These operations are performed 2-3 weeks before the actual shipping. If the operator judges and there is no problem in this simulation, the planned warehousing is actually carried out after a few weeks after the simulation.

The serving simulation function is as follows: Creation of issue list request master, 2. Preparation of a catering simulation master, 3. It consists of three functions: simulation instruction. The details of this function will be described below.

1. Issue list request master creation Use this function to create issue list request master. This delivery list request master is transmitted to the production management system 102, which is a higher-level computer, and the result of being expanded into item codes by the production management system 102, that is, the item code
The parts inventory management system 111 is notified of a delivery list including the number of units and delivery destinations.

More specifically, the function of “1. issue list request master creation” has four functions of registration, correction, deletion, and processing request.

(1) Selection of catering simulation menu screen When creating the delivery list request master, the operator selects the catering simulation screen.

(2) Registration of delivery list request master Next, the operator selects the delivery list request master creation function from the distribution simulation menu screen to display the delivery list request master creation screen. This screen example is the screen shown in FIG. The meaning of this display item is shown in Table 1 below.
Shown in.

[0039]

[Table 1] When the type input is accepted on this issue list request master creation screen, the issue list request master input screen corresponding to the entered type is displayed (not shown). Multiple screens are provided for the issue list request master input screen when specifying the product number and when specifying the item. For each of these screens, the display and processing content of the screen corresponding to the input item are defined.

When the input of each item is completed, the registration completion key is pressed to perform the registration completion process. Based on this information, the issue list request master record is edited and added to the issue list request master file. When the registration completion key is pressed, the screen returns to the display screen of FIG. 6 in which the input data is displayed.

(3) Deletion of the issue list request master When deleting the registered issue list request master, the delete mode key is pressed to switch the screen to the delete mode. In delete mode, if you enter the display "No." to be deleted and press the Enter key, enter the specified display "No." and press the Enter key to create the line of the specified display "No." The number is displayed in reverse. When the operator confirms this and presses the confirm key, the deleted lines are packed. Press the registration mode key to return to registration mode.

(4) Correction of the issue list request master When the registered issue list request master is corrected, the correction mode key is pressed to switch the screen to the correction mode. In the correction mode, if you enter the display "No." to be corrected and press the Enter key, enter the specified display "No." and press the Enter key, and the line of the specified display "No." is created. The number is displayed in reverse. When the operator confirms this and presses the confirm key, the modified lines are packed. Press the registration mode key to return to registration mode.

(5) Processing Request of Delivery List Request Master When sending the registered delivery list request master again to the host computer, that is, the production management system 102, the processing request is set in this processing. Normally, it is not necessary to perform this processing because the processing request is automatically set at the time of new registration and modification.

2. Delivery Simulation Master Creation With this function, the operator creates a delivery simulation master by referring to the delivery list notified from the delivery list master in the production management system 102 in “1. Create delivery list request master” on the screen. In addition, the created simulation master can be corrected and deleted.

(1) Selection of Serving Simulation Menu Screen When performing "serving simulation master creation", the operator selects the serving simulation menu screen.

(2) Registration of the serving simulation master The operator selects the serving simulation master updating function from the serving simulation menu screen. After this, the "Category Simulation Master Update Screen" such as the catered simulation master update screen (registration status)
(FIG. 7) is displayed. The contents of the extraction / editing process of this display item are shown below.

[0047]

[Table 2] (3) Modification of the serving simulation master To modify an existing placement simulation mask, press the modification mode key on the serving simulation master update (initial) screen. The following shows the display conditions of the catering simulation update (correction mode) screen.

(4) Deletion of the serving simulation master When deleting an existing serving simulation mask (for each serving request No.), the delete mode key is pressed on the serving simulation mask update (initial) screen.

3. Simulation instruction This function is a function to start the simulation based on the serving simulation master created by the serving simulation mask update function. In principle, this function should be performed separately from the normal warehouse operation hours. It should be noted that up to 1,000 serving requests N can be issued with one simulation instruction.
o. Input is enabled. Further, when a stockout occurs, the stockout list is output. The method and function of instructing simulation will be described below.

(1) Selection of the serving simulation menu When the "serving simulation instruction" is given, the operator selects the serving simulation menu.

(2) Simulation instruction The operator selects a simulation instruction from the serving simulation menu screen to display the simulation start instruction screen (FIG. 8). The contents of this display item are shown in the following table.

[0052]

[Table 3] 4. Deletion of issue list master This function is a function to delete the issue list master that is no longer needed. The issue list master has a maximum of 500 in this embodiment.
Although up to 500 items can be stored, the CPU discards new issue list masters without registering them when more than 500 items are registered. Therefore, with this function, the operator needs to delete the unnecessary data of the issue list master before performing new registration (before issuing the issue list request). The method and function for deleting the issue list master will be briefly described below.

(1) Selection of catering simulation menu When the delivery list master is deleted, the operator selects a catering simulation menu.

(2) Deletion instruction The operator selects the delivery list master deletion function from the catering simulation menu screen and displays the delivery list mask deletion screen (FIG. 9). The contents of this display item are shown in the following table.

[0055]

[Table 4]

[0056]

As described above in detail, according to the present invention, a planned shipping can be simulated in advance, and a shortage of parts or products can be detected at an early stage. You can smoothly leave without leaving.

[Brief description of drawings]

FIG. 1 is a plan view of the first floor of a distribution management warehouse.

FIG. 2 is a plan view of the second floor of the physical distribution management warehouse.

FIG. 3 is a side view of a distribution management warehouse.

FIG. 4 is a flow diagram showing an outline of a distribution center management system.

FIG. 5 is a diagram showing an outline of a shipping operation.

FIG. 6 is a screen example of a serving simulation.

FIG. 7 is an example of a screen of a serving simulation.

FIG. 8 is an example of a screen of a serving simulation.

FIG. 9 is an example of a screen of a serving simulation.

[Explanation of symbols]

 1a, 1b ... Flat warehouse 3 ... Small automatic warehouse 5 ... Loading station 6 ... Stacker crane 10 ... Bucket 11 ... Loading / unloading conveyor 15 ... Mini train road 17 ... Shipping conveyor 30 ... Large automatic warehouse 50 ... Medium automatic warehouse 70 ... Automatic sheet metal warehouse 100 ... Logistics center management system 101 ... Production planning system 102 ... Production management system 103 ... Main material inventory file 104 ... Main material inventory system 105 ... Parts work system 106 ... Machining progress management system

Claims (2)

[Claims] 1. An automatic warehouse which can be automatically carried in and out to store and manage parts, and which has a plurality of shelves for storing and managing the parts, and management and storage of the parts. In a distribution center management system comprising a central control device equipped with a terminal for controlling an automated warehouse, a delivery list master is previously received from the host computer of the central control device for the parts scheduled to be delivered, and the delivery list master is issued from this delivery list. On the basis of this delivery list master, edit the distribution list master to create a serving simulation master, and assume that the distribution center management system is delivered without actually delivering the parts from this serving simulation master. Serving of a distribution center management system, which is characterized by consisting of a serving simulation that is operated and serving Simulation method. 2. The distribution simulation method for a distribution center management system according to claim 1, wherein the distribution simulation management master uses the data of the distribution simulation master to carry out a planned shipment of a plurality of the parts at the same time and actually carry out the shipment. .