JPH069022A - Production physical distribution simulation system - Google Patents

Abstract

PURPOSE:To decide parameters closer to actuality by verifying dynamic relation between a factory warehouse and a physical distribution center. CONSTITUTION:This system is composed of a production center management part 1 for production control of products at a production center, a factory warehouse management part 2 for inventory management of a factory warehouse and a physical distribution center management part 3 for inventory management of a physical distribution center, and all the management parts 1 to 3 are ranked based on shipment amount of each product produced at the production center. And an inventory parameter which sets order point, maximum replenishing point and initial inventory amount for each rank and monthly average inventory amount for each of the ranked product are set, an order data per product whose order is received by the physical distribution center is set, and inventory of the factory warehouse management 2 is managed according to the inventory management of the physical distribution center management part 3 based on each inventory parameter, monthly average inventory amount and order data. Production of the production center management part 1 is managed according to the inventory management of this factory warehouse management part 2.

Description

Detailed Description of the Invention

[0001]

[Industrial field of application] The present invention relates to the capability and operation of each product from a production line to a distribution base in an industry where products produced at a production base are distributed via a factory warehouse and a distribution base. Setting value (lead time, ordering point, etc.)
The present invention relates to a production logistics simulation system capable of verifying the effects of

[0002]

2. Description of the Related Art Recently, due to advances in computer technology,
Various tasks that have hitherto been performed relying on human experience and intuition can now be performed accurately and quickly using a computer. For example, in a production line in which a product manufactured in a factory is temporarily stored in a factory warehouse and shipped in accordance with a customer's order, an inventory amount determination device for inventory management in the factory warehouse has been proposed.

This device has been limited to a limited range of models such as a model representing a factory and a factory warehouse, or a model representing a factory warehouse and a distribution base. In this case, a one-way relationship such as finding a local optimum solution between the factory and the factory warehouse or between the factory operation and the distribution base, or finding one of the optimum solutions and then finding the other solution I just asked.

That is, the production lines of the factory or those and the warehouse of the factory are modeled and the simulation is executed.
Using the parameters that gave satisfactory results within the range of the model, we performed a simulation of the logistics base,
Had determined the parameters of logistics.

[0005]

As described above, since the conventional inventory amount determining apparatus executes the physical distribution simulation based on the result obtained by executing the production line simulation, The simulation result of was not utilized in the simulation of the production line, so to speak, it became a one-way relationship, and it tended to be far from reality.

The present invention has been made in view of the above circumstances, and an object thereof is to carry out inventory management of a factory warehouse by a pull system by an order point system in which an order point and a maximum replenishment point are set for all ranks of ABC. , ABC for distribution center inventory management
The ordering point and maximum replenishment point are set for all ranks in the pulling method by the ordering point method, and by verifying the dynamic relationship in which each element interacts, it becomes a more realistic form It is to provide a production physical distribution simulation system for determining parameters as described above.

Here, the ordering point management system means that when the stock quantity is below the ordering point stock quantity preset as an ordering point,
This is a method of producing an appropriate amount within a range that does not exceed a preset limit inventory amount (maximum replenishment point inventory amount).

[0008]

[Means for Solving the Problems] In order to solve the above problems, a production distribution simulation system of the present invention stores a product manufactured at a production base and a production base management unit that manages production of products at the production base. It consists of a factory warehouse management department that manages the inventory of the factory warehouse and a distribution base management department that manages the inventory of the distribution base that stores the products shipped from the factory warehouse. Each produced product is ranked based on the shipment volume, and the inventory parameters that set the ordering point, maximum replenishment point, and initial inventory amount for each rank, and the monthly average inventory amount of each ranked product In addition to being set, the distribution base management unit is set with order data for each product ordered by the distribution base, and the product based on the inventory parameter, the monthly average inventory amount, and the order data. According to the inventory management of facilities management unit,
Inventory control of the factory warehouse management section is performed, and production management of the production site management section is performed according to the inventory management of the factory warehouse management section.

[0009]

[Operation] Each management section ranks each product produced at the production base based on the shipment amount, and the stock parameter and the rank that set the order point, maximum replenishment point, and initial stock amount for each rank. The monthly average stock amount of each divided product is set. In addition to this, order data for each product ordered by the distribution base is set in the distribution base management unit.

In the distribution base management section, the order point, the maximum replenishment point, and the initial stock amount of each rank represented by the number of months of inventory,
From the monthly average shipment amount of each rank product represented by the number (or weight etc.), first the ordering point of each product, the maximum replenishment point,
The initial stock quantity is converted into the number of pieces (or weight, etc.), and this is used as data for subsequent simulations. And
A change in the actual stock amount starting from the initial stock amount is simulated according to the order data, and a stock transfer order to the factory warehouse management unit generated as a result of this simulation is output to the factory warehouse management unit each time.

In accordance with the stock transfer order sent from the distribution base management section in this way, the factory warehouse management section simulates a change in the actual stock quantity, which also starts from the initial stock quantity, and the stock issue resulting from this simulation. The data is output to the factory warehouse management section and the production order is output to the production site management section.

The distribution base management unit adds the stock receipt data sent from the factory warehouse management unit to simulate the actual stock amount thereafter. In addition, the production base management unit performs a production simulation of a required product according to the production order from the factory warehouse management unit, and outputs the resulting production amount data of the product to the factory warehouse management unit. The factory warehouse management section simulates the actual stock quantity thereafter by adding the production quantity data sent from the production base management section.

As described above, the models of the production base, the factory warehouse, and the physical distribution base are mutually coupled by the respective management units and interact with each other, so that the relationship of the respective models suitable for the actual flow can be verified. .

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram showing an electrical configuration of a production physical distribution simulation system of the present invention.

The production logistics simulation system of the present invention is a production site management unit 1 for managing production of products in a production factory, and a factory warehouse management for inventory management of a factory warehouse for storing products produced in this production factory. It is composed of a part 2 and a distribution base management part 3 which manages the inventory of the distribution bases that store the products shipped from this factory warehouse. The production management part 1, the factory warehouse management part 2, and the factory warehouse management. The section 2 and the distribution base management sections 3 ... Are bidirectionally connected. Further, each management unit 1, 2, 3 reads out each data stored in the database 4 and performs each operation.

The database 4 stores order data, a product number (product) master, and production capacity data, which will be described later. Here, the order data is the actual order data of the past arbitrary period (or the data predicted from the actual order data), and the order date, product classification code, product number code, sales and sales section code, quantity, etc. It is classified. In addition, the product number master holds data for each product number, and is a management unit (m ² , case, etc.) of quantity in each model of production base, factory warehouse, and distribution base.
It is used to convert the unit (pieces) of order data, and is classified into each item such as a product number code, a product classification code, an area (m ² ) per piece, the number of pieces, and the packing weight. . The production capacity data is data that holds the production line and its capacity for each product category, and is classified into each item of product category, production line, and production capacity (m ² / day).

Here, in order to explain the operation of the production physical distribution simulation system having the above configuration, the following situation is set.

That is, it is assumed that the data shown in FIG. 2 is set in the database 4 as a sample of the order data of the distribution bases DP1, DP2 ... Provided to the distribution base management units 3.

For example, at the distribution base DP1, the product X is
500 pieces on April 1st, 700 pieces on April 2nd, product Y is 70 pieces on April 1st, 90 pieces on April 2nd, product Z is April 1st It shows that there are 20 orders and 10 orders on April 2nd.

Then, according to such an order, each product is first ranked (ABC analysis).

Here, in the ABC analysis, products with a large shipping amount indicated by the shipping plan data are sequentially added, and the cumulative number at this time is divided by the total number of all products indicated in the shipping plan data. When the value is expressed in%, the product whose value falls within the range of -80% is ranked A, 80-95%.
The products which fall within the range are ranked B, and the products falling within the range of 95 to 100% are ranked C. That is, products with a large shipment amount are classified into the A rank, and as the shipment amount decreases gradually, the products are sequentially classified into the B line and the C rank. Such a classification method is a method generally used in the field of production control.

FIG. 3 shows an example of the result of ranking each product in this way.

In this embodiment, the product X is rank A, the monthly average shipment amount at the factory warehouse is 13,600, the monthly average shipment amount at the distribution point DP1 is 3000, and the distribution point D is
The monthly average shipment amount at P2 is 1200, the product Y is rank B, the monthly average shipment amount at the factory warehouse is 5600, the monthly average shipment amount at the distribution point DP1 is 160, and the distribution point D is
The average monthly shipment in P2 is 320 pieces, the product Z is C rank, the monthly average shipment in the factory warehouse is 1000 pieces, the monthly average shipment in the distribution base DP1 is 100 pieces, the distribution base DP.
The average monthly shipment in 2 is 100. Such an ABC analysis result is stored in the database 4.

Further, it is assumed that the database 4 is set with the inventory parameters shown as a list in FIG. 4 as the order point, the maximum replenishment point, and the initial inventory amount at the factory warehouse and the distribution bases DP1 and DP2. . The value of the inventory parameter is represented by the number of months of inventory. The value of this inventory parameter can be arbitrarily changed.

The inventory simulation is performed based on the above-mentioned respective data. In this embodiment, the distribution base D
The operation will be described by focusing on the product X of P1.
Further, FIG. 5 shows the result of the simulation performed in the following description, and the description will be given with reference to this result as well.

From the above data, the ordering point for the product X at the distribution base DP1 is 900 because the product X is rank A, and therefore the monthly average shipment quantity (3000 pieces) and the ordering point (0.3).
The number is (= 3000 × 0.3). Similarly, the maximum replenishment point is 2100 pieces (3000 × 0.7), and the initial stock quantity is 1500 pieces (3000 × 0.5).

That is, the simulation is started with the actual stock quantity of the product X being 1500 pieces.

Since the order quantity of the product X on April 1st is 500 according to the table shown in FIG. 2, 1000 pieces obtained by subtracting the 500 pieces from the actual inventory quantity of 1500 pieces are April 1st. The actual daily inventory amount. Next, Product X April 2
The daily order quantity is 700 pieces, so subtracting this 700 pieces from the actual stock quantity of 1000 pieces gives 4 pieces.
It is the actual inventory on the 2nd of each month. Here, the ordering point for product X is 9
Since the actual inventory quantity is less than the order point at this point, the physical distribution base management unit 3 issues a stock transfer order to the factory warehouse management unit 2.

The output stock transfer order is obtained as follows.

That is, the lead time for transportation is 2
If the actual number of working days in one month is 20 days, the average shipment amount during the transportation lead time is

[0032]

## EQU1 ## 3000 × 2 ÷ 20 = 300. Therefore, the stock transfer order considers the average shipment quantity (300 pieces) during this transportation lead time,

[0033]

## EQU00002 ## The maximum replenishment point (2100) -actual inventory quantity (300) + average shipment quantity during transportation lead time (300) = 2100 pieces.

Next, the order quantity of product X on April 3 is 4
Although the number is 00, in this case, the order quantity exceeds the actual stock quantity, so that the product is out of stock. And in this case, the order will not be shipped separately.
Until the full quantity is filled, it will be carried over as a back order from the next day.

On the other hand, when the factory warehouse management unit 2 receives a stock transfer order from the physical distribution base management unit 3 on April 2, the same process as the physical distribution base management unit 3 is performed, and the actual inventory amount becomes the order amount ( In this case, if the stock transfer order of 2100 pieces is satisfied, after the transportation lead time set for each distribution base (the lead time of the distribution base DP1 is 2 days), the distribution base DP1 is reached. To 2
The process of storing 100 products is performed. Further, if the actual inventory quantity is below the ordering point, a production request is made to the production site management unit 1. Here, the ordering point of the factory warehouse management unit 2 is 13600 × 0.3 = 4 from FIGS. 3 and 4.
It is 080.

In the production base management unit 1, the factory warehouse management unit 2
In response to the production request from, the production capacity data and the like are collated to allocate to the production line determined for each product, and after the completion of production, the warehousing process to the factory warehouse management unit 2 is performed.

On the other hand, in the physical distribution base management section 3, since the factory warehouse management section 2 receives 2100 pieces on April 4, the actual inventory amount at this point is 2400 pieces (= 300 + 2).
However, since the order quantity on that day is 800 pieces, the actual inventory quantity is 240 pieces, which is 400 pieces carried over from April 2nd and 800 pieces.
Subtract from 0 pieces, and use the subtracted 1200 pieces as the actual stock amount for the day.

Next, the order quantity of product X on April 5 is 7
Since it is 00 pieces, the actual stock quantity of 1200 pieces is subtracted from the 700 pieces to obtain 500 pieces, which is the actual stock quantity on April 5. Then, at this point, the actual inventory quantity of the product X is again below the ordering point (900 pieces), so that the distribution base management unit 3
Performs the same processing as April 2, and the factory warehouse management department 2
Will issue a stock transfer order. That is, the stock transfer order amount at this time is

[0039]

## EQU00003 ## Maximum replenishment point (2100) -actual inventory quantity (500) + average shipment quantity during transportation lead time (300) = 1900 pieces.

[0040]

According to the production distribution simulation system of the present invention, since the production base, the factory warehouse, and the distribution base operate in synchronization with each other, it is possible to perform a more realistic simulation as a whole.

[Brief description of drawings]

FIG. 1 is a block diagram showing an electrical configuration of a production physical distribution simulation system of the present invention.

FIG. 2 is a table showing an example of order data.

FIG. 3 is a table showing the results of ABC analysis.

FIG. 4 is a table showing an example of set values of inventory parameters.

FIG. 5 is a table showing simulation results at a physical distribution base.

[Explanation of symbols]

 1 Production base management department 2 Factory warehouse management department 3 Logistics base management department 4 Database

Claims (1)

[Claims] 1. A production site management unit that manages production of products at a production site, a factory warehouse management unit that manages inventory of a factory warehouse that stores products manufactured at the production site, and a factory warehouse that ships products. It consists of a distribution base management unit that manages inventory of distribution bases that store products, and each management unit ranks each product produced at the production base based on the shipment amount, and for each rank. The order point, the maximum replenishment point, the inventory parameter that sets the initial inventory amount, and the monthly average inventory amount of each ranked product are set, and the distribution base management unit sets the products ordered by the distribution base. Order data is set for each, and inventory management of the factory warehouse management unit is performed according to inventory management of the distribution base management unit based on the inventory parameter, monthly average inventory amount, and order data. A production distribution simulation system, wherein production management of the production site management unit is performed according to inventory management of the management unit.