JPH07282140A - Production schedule system - Google Patents

Abstract

PURPOSE:To judge the planning possibility of a production schedule corresponding to received order contents. CONSTITUTION:The production plan is generated by bringing respective shop workloads required for the completion of an item to the earlier side from a completion request date based on the completion request of the item. When an order is received from a customer, the completion request for satisfying the received order contents is successively assigned. When the completion request to be assigned is not present, the completion request for satisfying the received order contents is added and the production schedule is regenerated. Then, the workloads before the present date of respective shops in the generated production schedule are compared with the workloads by the production schedule not assigned for the received order from the customer. When the overloads of the shops is not larger, the production schedule assigned for the received order from the customer is judged as executable by changing the production schedule not assigned for the received order from the customer for the shop.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production planning system for producing a production plan in a manufacturing system, and more particularly to a production planning system capable of flexibly coping with a change in a required number.

[0002]

2. Description of the Related Art As a conventional technique relating to production planning, the supply capacity of a parts supply shop and the production capacity of an assembly shop, which are described in Japanese Patent Laid-Open No. 63-306861, are compared with each other and consumption of materials or parts is considered. There is known a technique for adjusting and determining a product production amount so that the supply amount and the supply amount are kept in balance.

Further, there is known a technique described in Japanese Patent Application Laid-Open No. 2-311250 for supporting adjustment of a production plan in which a problem occurs.

Further, when the current production plan described in Japanese Patent Laid-Open No. 4-145573 cannot meet the delivery time required by the customer, it is assumed that the parts and materials of the product which meet the demand will be procured from that point onward. There is a known technology for changing the date and considering the deadline that can be met by this production plan as the delivery date to the customer.

[0005]

However, after the production plan is once generated, the actual required number may increase from the planned required number. This is the case when the number of orders from the customer is greater than the planned number. In such a case, it is desirable to review the production plan and regenerate a production plan that satisfies the actual required number as much as possible. Regeneration of the production plan is generally performed by regenerating the production plan so as to satisfy the required number actually required. However, when the original production plan has no margin, In many cases, the production plan regenerated in this way includes problems such as the start date of the work being before the current date and the need for materials and parts out of stock. Therefore, in such a case, it is necessary to solve the problem and adjust the production plan so as to meet the actual required number as much as possible.

However, the technique described in Japanese Patent Application Laid-Open No. 63-306861 cannot meet such requirements.

Further, according to the technique disclosed in Japanese Patent Laid-Open No. 2-311250, the planner assists the work of adjusting the production plan of the production plan having a problem, but the problem location is detected and the cause of the problem occurrence is investigated. Also, since it does not support the determination of the details of adjustment, the planner must do all of this independently.

Further, according to the technique described in Japanese Patent Laid-Open No. 145573/1992, if the current production plan cannot meet the delivery date requested by the customer, the parts and materials of the product complying with this request are procured from that point onward. Therefore, the production plan is changed, and the due date that can be handled by this production plan is considered as the reply delivery date to the customer. However, there are cases where a product that is scheduled to be completed after the customer's requested delivery date is not actually needed, and in this case, considering the workload of the manufacturing system and the inventory quantity,
If you change the production plan of the product that is scheduled to be completed after this customer's requested delivery date, from that point on, it will be faster than when you procure the parts and materials of the product that meets this requirement (for example, make sure that the customer's required delivery time is In some cases, the required product can be completed), and a production plan that is totally satisfactory can be generated.

Therefore, according to the present invention, even when the actual required number is larger than the planned number, the planner can easily change the production plan so as to satisfy the actual required number as much as possible. The purpose is to provide a production planning system that can support

[0010]

In order to achieve the above object, the present invention takes, for example, a part of a manufacturing process for manufacturing a final item, and is used as a part of the final item in the carried step. Or a production planning system for generating a production plan of a manufacturing system having a plurality of shops for producing the final item, when it is required to supply the required number of the final item at a necessary time, The final item to be completed in the completion schedule that specifies the final item's completion schedule is not allocated to other requirements to be completed before the specified required time,
If there is more than the required number of final items, this is allocated to the request, and if not, allocation means for adding the completion schedule of the final item satisfying the request to the completion schedule, and completion. Based on the schedule, set the work period of each process to manufacture each final item so that the amount of work of each process generated by the production plan on each day does not exceed the capacity of the corresponding shop on each day. , A means to generate a production plan by moving forward from the scheduled completion date, and for each process, from the generated production plan, manufacture all items scheduled to be completed in the process on that day on each day. If the amount of work allocated for each process exceeds the capacity of the shop on that day for each process, the completed work is calculated by totalizing the amount of work required for As described above, the amount of work included in each completed work amount is assigned in order from the latest scheduled completion date to the past from the corresponding expected completion date, and the means for allocating to each day and each process are dated before the current date. If the workload is allocated to the last item, the final item that has not been allocated to the request and the final item in question during the period in which the day when the workload is reassigned to the previous day continues from the present date toward the future. It is determined whether or not the total amount of work for producing the item used as a part of the item exists more than the total amount of work assigned to the day before the current date. , It is determined that there is a possibility of making a production plan that meets the completion schedule of the final item assigned to the requirement by changing the production plan for the final item not assigned to the requirement. It provides for the production planning system characterized by having a production plan execution determining means for.

[0011]

According to the production planning system of the present invention, based on the produced production plan, for each process, the total amount of work required to manufacture all the items scheduled to be completed in the process on the day concerned is accumulated. If the amount of work allocated for each process exceeds the capacity of the shop on that day for each process, the amount of work that has been exceeded is reassigned to the previous day, so that the completed date is late. For each means and process that allocates the amount of work included in each completed work amount in order from the corresponding planned completion date to the past, the work amount is assigned to the day before the current date. In the case of the last day, the last item that has not been allocated to the requirement and the item that is used as a part of the last item during the period in which the amount of work is reassigned to the previous day is continuous from the present date toward the future. It is determined whether or not the cumulative amount of work for producing is greater than or equal to the cumulative amount of work assigned to the day before the current date, and if there is, the process is allocated to the request. It is determined that there is a possibility of drafting a production plan that meets the completion schedule of the final item allocated to the requirement by changing the production plan for the final item that does not exist.

Therefore, based on this judgment result, the planner determines that the production plan assigned to the requirement, that is, satisfying the actual completion schedule is required for each process in question. It is possible to immediately recognize whether or not it is possible to make a plan by changing the production plan for the final item that is not allocated to the requirement. Therefore, along with this, if it can be recognized that it is possible to make a plan by changing the production plan for the final item that is not allocated to the requirement, the work in the problematic process occurs. The production plan is adjusted so as to cancel the production plan for the final item that has not been allocated to the above requirements, and the production plan that meets the actual required completion schedule and is not problematic as a whole is prepared. be able to.

[0013]

EXAMPLE An example of the production planning system according to the present invention will be described below.

FIG. 1 shows the configuration of the production planning system according to this embodiment.

In the figure, 1000 is a production planning system, 11
00 is an ordering system, 1200 is a manufacturing system, 130
0 is a forecast production planning system.

Using the make-to-stock production planning system 1300, the planner creates a completed schedule of products based on the expected quantity of orders. The completed schedule of the product is
It is created as a set of production request information, each of which is assigned a note number, which specifies a product name, the number of products, and a completion date group.
The completed schedule of the created product is passed to the production planning system 1000.

The production planning system 1000 creates a production schedule for a product in the manufacturing system 1200 based on the finished schedule for the product.

The order-accepting system processes an order from a customer, and passes order-accepting information designating the number of orders and a requested delivery date to the production planning system 1000. In addition, the production planning system 10
From 00, the answer of the contract delivery date based on the production schedule is obtained.

The manufacturing system 1200 is a system for actually manufacturing a product according to the production plan established by the production planning system 1000.

The production planning system 1000 includes a data storage device 11 for storing a product completion schedule, order information, a production schedule and information about the manufacturing system 1200, and a planner. And a data input / output device 12 for providing the user interface of the above.

Further, it has an MRP control device 2, an MRP development device 8, a lead time calculation device 1, a work amount calculation device 3, a work amount analysis device 27, and a production plan execution judgment device 101.

Further, it has a problem analysis device 7, a production capacity adjustment device 4, a completion date adjustment device 5, an alternative shop adjustment device 6, a work start sequence adjustment device 33, a production amount adjustment device 104, and a plan deletion device 27. There is.

Now, in this embodiment, the manufacturing system 1200 is modeled as follows.

First, each shop is grouped into a shop group. Each shop group is a group of shops that can substitute for each other and do not have a mutual relationship in the processes to be carried out. For example, a shop group for a shop that assembles and a shop that performs painting. About the shop group and the shop group about the shop that performs the processing.

Next, the shop groups are arranged by the method of topological sort.

That is, regarding the production of any product,
Even if the shops that carry out each process are arranged in order from the earlier process to the production process, and the number of the shop group to which each shop belongs is arranged corresponding to the arranged shops, the smaller number always precedes the larger number. Number each job group so that As a result, in the production of any product, the number of the shop group to which the shop that carries the earlier process belongs is smaller than the number of the shop group to which the shop that carries the later process belongs. Therefore, a smaller-numbered shop group is set as an upstream shop group, and a larger-numbered shop group is set as a downstream shop group.

The products produced in each process are called items, and the relationship between each item and the shop that manufactures the item is preliminarily set in the data storage device 11 as information about the manufacturing system. To do. Further, in this embodiment, a system for procuring items such as materials that need to be procured from outside is also handled as a shop. In this embodiment, this shop is called a procurement shop. Procurement shop is a system for ordering and procuring net requirements and items, which are obtained by subtracting the inventory amount from the requirements of items.

The manufacturing system 1200 also manages the inventory quantity of each item, and sends the current inventory status to the data storage device 11 of the production planning system 1000. Items processed at each shop and items procured at the procurement shop are added to the inventory.

Hereinafter, the production planning system 1 according to this embodiment
000 operation will be described.

Production planning system 1000 according to the present embodiment
First creates a production plan based on the completed schedule created by the expected production planning system 1100.

FIG. 2 shows a processing procedure for production plan generation of the production planning system according to this embodiment.

First, after storing the completed schedule received from the expected production planning system 1100 in the data storage device 11, and receiving the required amount expansion instruction 30 from the data input / output device 12, each note in the completed schedule is received. The product (final item) name in the production request information corresponding to the number, the total required amount of the final item, and the completion date are read from the data storage device 11 (201).

Next, the MRP control device 2 controls the operation of the MRP expansion device 8 so that each shop belonging to the most downstream shop group (202) is sequentially processed for each item manufactured in the shop. The inventory quantity stored in the data storage device 11 is subtracted from the required quantity to find the quantity that actually needs to be manufactured in the shop, and set as the net required quantity of each item manufactured in the shop (203, 204).
Next, for each shop, the calculated net required amount and completion date of each item are passed to the work amount calculation device 40 as data 3. At this time, the required amount for each order number is also obtained.

The work amount calculation device 40 calculates the completed work amount 26 for each shop (208) and transfers it to the lead time calculation device 1. Here, the completion work amount refers to the amount of work of the shop required for manufacturing all the items whose completion date is that day, for each day.

On the other hand, in the lead time calculation device 1, the lead time 14 of each item is obtained based on the completed work amount 26 obtained for each shop and the preset production capacity 13 of the shop (207, 208, 209). ). The details of the calculation method of the lead time will be described later.

In the MRP expansion device 8, each item is sequentially set as an expansion target item, and the lead time 14 of the expansion target item obtained by the lead time calculation device 1 is subtracted from the completion date to determine the manufacturing start date of the expansion target item. Then, the items (sub-items) necessary for manufacturing the expansion target items are obtained, the determined start date is set as the completion date of the sub-items, and the required amount expansion process for the total required amount is calculated for each sub-item. Then, the quantity of each child item required to manufacture the expansion target item is obtained (210 to 113).

As described above, since the production plan for the most downstream shop group is completed, the MRP controller 2
Sequentially repeats the processes after the reference numeral 103 in FIG. 2 for the upstream shop group (214, 215). However, for the procurement shop, the period required for the procurement of the item is simply set as the lead time (procurement lead time), and the start date obtained from the lead time is set as the date for ordering the item.

The production planning system according to the present embodiment thus carries out the production planning (MRP regeneration).

Next, the lead time calculation performed by the lead time calculating device 1 described above will be described.

As described above, the lead time calculation device 1
Predicts the lead time for each process, considering the load on each shop.

By the way, in a flow shop in which each shop carries out a fixed work on the process flow, there is a tact time unique to the line, and there is an optimum production speed and a lead time per piece.

Further, in the job shop which takes charge of the jobs submitted by each shop, the average lead time increases almost in proportion to the in-shop work in process, while the production speed increases in the work in progress. It is well known from past studies using queuing theory that the saturation is not reached and increases at a certain level. The fact is that there is an optimal work-in-progress level and production speed, and even if a job is submitted,
It indicates that there is a point that the lead time per item only increases and the production speed almost increases.

Therefore, it is necessary to obtain the lead time so as to generate a production plan that can maintain the optimum production speed.

Therefore, in this embodiment, the lead time is predicted by the method shown in FIG. 3 as follows.

As shown in the figure, in the present embodiment, the lead time of each process carried out by each shop is obtained. Now, the cycle time (input interval = output interval of one item) at the optimum production speed at each shop,
It is assumed that the lead time for each item is known for each shop.

As described above, first, the work amount calculation device 4
0 determines the amount of completed work of the target shop each day. The completion work amount is the total work amount of the items whose completion date is the relevant date, and as shown in FIG. 3a, the completion work amount is the number of items and the standard required to manufacture one of the items. Time ST
The product of is the sum of all items whose completion date is the relevant date. At this time, the amount of work on the target shop for each order using the item whose completion date is the relevant day is also calculated.

Next, as shown in FIG. 3b, the work amount distribution and the input timing are obtained.

That is, the work amount distribution is determined while the load is moved forward from the future to the past. For example, the work load distribution of the item group A completed on the nth day is determined as follows. First, set the completion time (= the production time of the last one) to coincide with the end of the completion date. Next, the width between the first one production time and the last one production time is obtained as the normalized completion work amount × standard cycle time of the day, and the first one production time is determined. Further, the lead time for each item is subtracted, and the first one is input time, that is, the start time of A. However, like the item group B, if the first production time of the item group A that will be completed on the next day is before the completion date of its own, make the completion time of B coincide with this. Set to.

Here, the normalized completed work amount means the standard work amount (S of items to be worked in the shop concerned).
It is normalized by dividing the weighted average value of T by the work quantity ratio). Also, the standard cycle time is the cycle time of the items that are worked in the shop,
It is a weighted average value based on the work quantity ratio. The standard lead time per piece is the weighted average value of the lead time per piece of the item worked in the shop, which is based on the work quantity ratio.

Next, as shown in FIG. 3c, the interval between the start time and the completion time is set as the read time. If the work of the item completed after the next day is delayed before the completion date, the lead time will be increased accordingly.

By the way, in the present embodiment, as will be described later, the production plan is adjusted by changing the setting of the ability of the shop so that it is different for each day. Here, the operation in this case will be described.

In this case, when the ability becomes α times,
Since the standard cycle time and the standard read time are 1 / α times, the width and the inclination in FIG. 3c should be 1 / α. However, this makes the calculation complicated at the turning point of the ability. Therefore, in this embodiment, it is set as shown in FIG. That is, the ability increased α times means that the time axis has expanded by α times, and on this expanded / contracted time axis,
As in FIG. 3, the width and the inclination are set and the lead time is read.

As described above, the lead time calculating apparatus 1 sets the lead time of each process for each shop in consideration of the total load of the shop.

As described above, the parameters for prediction are necessary to predict the lead time. The prediction parameters are ST, cycle time, and lead time per piece. These are the manufacturing system 12
00 as information about the data storage device 11
It is stored in advance. However, the production performance information may be obtained from the manufacturing system, an accurate prediction parameter may be calculated based on the production performance information, and may be provided to the lead time calculation device 1.

The lead time calculation device 1 can also be realized by using a pattern conversion model, for example, a neural network. The neural network is
Since it has a pattern conversion ability between the input data and the output data and a pattern learning ability, the lead time calculation device 1 and the work amount calculation device 3 learn each neural network by using the following data, for example. By doing so, the lead time for a new input can be calculated by pattern conversion.

Input: Ability of each shop, completed work output: Lead time In addition, regarding the theory of the neutral network, Rumelhardt Dee, McLarend JL and the PDP Research Group, 19
86, Parallel distributed processing: MI Press (Remelhart DE, McC
lelland JL and The PDP Research group, 1986,
Parallel Destributed Processing: MIT Press).

Even when the neural network is used as the lead time calculation apparatus 1, a prediction parameter is necessary. The prediction parameter is a set of bond strength values between cells of the neural network. These perform learning of the neural network based on the production performance data obtained from the manufacturing system.

In this way, the production and procurement plan for each order number is created by the production planning system 1000 for each shop according to the completed schedule created by the expected production planning system 1300, and the data storage device is used. 11 is stored. Now, at this point, it is assumed that the production and procurement plan can be created so that the completed schedule can be satisfied, that is, the start date and order date before the present are not set.

After that, when the order receiving system 1100 sends the order receiving information designating the ordered products, the required number of products, and the required delivery date to the data storage device 11, the MPR control device receives 2, which is a certain number of days before the required delivery date. As the completion date, the order number attached to the production requirement information that created the production plan is assigned to this. When assigned, the requested delivery date is set as the contract delivery date, and the ordering system 1100 is answered via the data storage device 11. Further, the correspondence between the order number and the order information assigned thereto is stored in the data storage device 11.

However, if there is an order received that exceeds the planned quantity in the completed schedule created by the forecast production planning system 1300, there is no note number that can be assigned to the order anymore. Create production request information that indicates the product name, completion date, and quantity that satisfy the order received by the information, and add a new order number to complete the schedule.
In addition to this, assign this order number to order information. And
The MRP expansion device 8 is instructed to regenerate the production plan.

Now, the MR instructed to regenerate the production plan
The P expansion device 8, the work charge calculation device 3, and the lead time calculation device 1 read out the current stock amount from the data recording device 11 and prepare the production and procurement plan for each order number for each shop as described above. , The data storage device 11, but at this time, the work amount analysis device 27 and the production plan determination device 101.
In terms of the amount of work, whether or not a viable production plan that satisfies this new completed schedule has been drafted, and if not, the production requirements for all the orders assigned to the order, It is determined whether or not a viable production plan that satisfies the above can be drafted. In addition, the MRP expansion device expansion device 8,
The production plan determination device 101 determines whether or not a feasible production plan satisfying the new completed schedule has been drafted in terms of the inventory quantity of the items to be procured from the outside. It is determined whether or not a viable production plan that satisfies the production requirements of all the order numbers assigned to the orders can be drafted.

First, the operation of judging the work amount performed by the work amount analyzing device 27 and the production plan judging device 101 will be described.

That is, in the lead time calculation device 1,
As described above, the actual required lead time is calculated by moving the completed work amount data for each completed day unit forward from the future toward the present in accordance with the production capacity (time) of the shop. Therefore, as shown in FIG. 5A, the cumulative total of the overloads of the shops when the work is performed from the current date is the cumulative total of the workloads existing before the current date 500. In addition, on each day, the amount of work to be done the day before is the overload amount for that day.

The work amount analyzing device 27 obtains the overload amount for each shop from the lead time calculating device 1 on each day, and if there is no completed work amount to be defeated on the day before the present day, the work amount analyzing device 27 instructs the production plan judging device 101. Then, the work amount analysis device 27 determines that an executable production plan satisfying the new completed schedule has been drafted for this shop in terms of work amount, and the data storage device 11 Memorize that.

On the other hand, if there is a completed work amount to be defeated on the day before the present day, the work amount analysis device 27 determines the overload amount on each day when the overload amount continuously exists in the future from the present day (see FIG. 5b). ) Is passed to the production plan determination device 101.

In this case, the production plan judging device 101 judges whether or not a viable production plan satisfying the production request of the order number assigned to the order can be made as follows.

That is, by dividing the period in which the overload amount is continuous into a plurality of periods and canceling the production of the order number that is not assigned to the order, the overload amount on the first day of each period is resolved within that period. Determine if it is possible.

For example, in the example of FIG. 5c, (1) +
The amount of work a + b or more before the first day of the period (2) exists within the period (1) or (1) + (2) as the amount of work corresponding to the order number not assigned to the order. Or the work amount equal to or larger than the overload amount b on the first day of the period (2) exists within the period (2) as the work amount corresponding to the order number not assigned to the order, and , The work corresponding to the order number which is not assigned to the order, the work amount of which is equal to or more than the overload amount a obtained by subtracting the overload amount b of the first day of the period (2) from the work amount a + b before the period (1) If the quantity exists within the period (1), for this shop, by changing the production schedule of the order number not assigned to the order, the production request of the order number assigned to the order is changed. It is determined that a viable production plan that satisfies The chromatography data storage device 11, to that effect storage. At this time, note numbers that are not assigned to orders and that generate work during a period in which there is a continuous overload from the present date to the future are also stored as schedule change candidate note numbers. You may keep it.

In other cases, it is determined that, for this shop, an executable production plan that satisfies the production request for the order number assigned to the order cannot be made, and the data storage device 11 is so notified. Remember.

When the above judgments have been made for all the shops, it is judged that a viable production plan satisfying the new completed schedule has been drafted for all the shops involved in the production of each order number. Whether or not it is determined for each order number assigned to the order,
If it is determined that a viable production plan that satisfies the new completed schedule has been drafted for all shops, it is determined that a production plan that satisfies the production requirements corresponding to the relevant order number has been drafted, and the data It is stored in the storage device 11.

If it is determined that a viable production plan that satisfies the production requirement of the order number assigned to the order is not possible for any of the shops involved in the production of the respective order numbers, It is determined that it may not be possible to make a production plan that satisfies the production requirements corresponding to the order number,
The fact is stored in the data storage device 11.

In other cases, it is determined that a feasible production plan satisfying the production requirement corresponding to the order number can be planned by changing the production schedule of the order number not allocated to the order. Then, the fact is stored in the data storage device 11.

Next, the judgment made by the MRP expanding device expanding device 8 and the production plan judging device 101 in terms of the inventory quantity of the items procured from the outside will be described. Even if a feasible production plan that satisfies the new completed schedule is drafted in terms of the amount of work, this decision makes it impossible to carry out the drafted production plan due to the lack of parts procured from outside. This is due to the fact that there are cases.

Now, a certain period (procurement lead time) is required to procure an item from the outside. Therefore, at the current date, the inventory amount (planned inventory amount) from the current date to the date when the procurement lead time is added to the current date is fixed.

On the other hand, assuming that a feasible production plan satisfying the new completed schedule is prepared from the viewpoint of the amount of work, in this production plan, the start date of each work occurs only after the current date. Absent. That is, the required amount of the item to be procured from the outside, which is obtained by the MRP expanding device 8 as described above, occurs only after the current date. Therefore, in this judgment, the required amount is compared with the inventory amount (planned inventory amount) from the current date to the date when the procurement lead time is added to the current date, that is, the period when the additional order is not in time, and the production from the inventory side is performed. Determine the feasibility of the plan.

The production plan determination device 101 determines the required amount for each day of the item to be procured from the outside, which has been determined by the MRP developing device 8 as described above, and the fixed inventory amount for each day (planned inventory amount). Are compared for each item.

Then, with respect to the items for which the confirmed inventory quantity (scheduled inventory quantity) of each day does not fall below the required quantity of each day, a feasible production plan satisfying the new completion schedule is drafted. Data storage device 11,
Memorize that.

On the other hand, for items for which the fixed inventory quantity (scheduled inventory quantity) for each day may fall below the required quantity for each day, the required quantity for each day is allocated to the order Note. The required quantity corresponding to the number is calculated, and this is compared with the confirmed inventory quantity (planned inventory quantity) for each day. If the confirmed inventory quantity (scheduled inventory quantity) for each day does not fall below the required quantity corresponding to the order number allocated for the order for each day, it is not allocated for the order. By changing the production schedule of the order number, it is determined that a feasible production plan that satisfies the production request of the order number assigned to the order can be drafted for this item, and the data storage device 11 is notified of that fact. Remember. In addition, at this time, of the order numbers corresponding to the required amount existing from the current date to the date when the procurement lead time is added to the current date, the order number not assigned to the order is also scheduled. You may make it memorize | store as a target note number.

In FIG. 6, as an example, the lead time is 5
For the items of the day, the confirmed inventory quantity of each day (planned inventory quantity) is less than the requirement quantity of each day, but it is less than the total requirement quantity corresponding to the order number assigned to the order of each day. The case where there is no case is shown.

Further, if the decided stock quantity of each day (planned stock quantity) may be less than the total quantity of the required quantity corresponding to the order number allocated to the received orders of each day, regarding this item, It is determined that a feasible production plan that satisfies the production request for the order number assigned to the order is unplanned, and the data storage device 11 stores that fact.

Then, after making the above determinations for all externally procured items, a feasible production plan satisfying the new completed schedule is drafted for the externally procured items required for the production of each order number. If it is determined that a viable production plan that satisfies the new completed schedule has been drafted for all items, it is determined whether or not it has been determined that it has been done. Then, it is determined that a production plan satisfying the production requirement corresponding to the order number has been drafted and stored in the data storage device 11.

When it is determined that it is not possible to formulate an executable production plan that satisfies the production requirement corresponding to the order number for any of the externally procured items required for the production of each order number. Determines that it may not be possible to make a production plan that satisfies the production requirements corresponding to the order number,
The fact is stored in the data storage device 11.

In other cases, it is determined that an executable production plan satisfying the production requirement corresponding to the order number can be planned by changing the production schedule of the order number not allocated to the order. Then, the fact is stored in the data storage device 11.

Then, the production plan judging apparatus 101 determines the amount of work and the amount of inventory according to the determination from the amount of work and the amount of stock of each order number allocated to the order thus obtained. If it is determined by both parties that a viable production plan that satisfies the production requirement corresponding to the order number can be planned by changing the production schedule of the order number that is not assigned to the order, The final judgment is that it is determined that a feasible production plan that satisfies the production requirements corresponding to the order number can be planned by changing the production schedule of the order number that is not assigned to the order. If it is determined that there is a case where it is impossible to make a production plan that is stored in the data storage device 11 and that satisfies the production request corresponding to the order number, at least one of the production requests corresponding to the order number is generated. It is stored in the data storage device 11 as a final judgment that a satisfying production plan may not be able to be drafted. In other cases, a viable production plan satisfying the production request corresponding to the order number is ordered. By changing the production schedule of the order number not assigned to
The data storage device 11 makes a final decision that planning is possible.
Remember.

By the way, the generation of the production plan as described above, the confirmation of whether there is a problem in the generated production plan, and the adjustment of the production plan when there is a problem are controlled by the physical data input / output device 12. Through a traditional user interface.

In the following, the operation of the user interface is checked to confirm whether or not there is a problem in the generated production plan of the production planning system, and the operation of adjusting the production plan when there is a problem. explain.

The data input / output device 12 is, for example, a display device such as a cathode ray tube display device, a keyboard,
It has an input device such as a mouse.

First, a graphic user interface displayed on the display unit of the data input / output unit 12 for receiving a production plan generation instruction will be described.

FIG. 6 is an initial screen initially displayed by the data input / output device 12 when the production planning system is activated.

In FIG. 7, when the "initial plan" command 41 in the command menu is picked with the mouse,
The data input / output device 12 instructs the MRP control device 2 to execute MRP.

Then, according to this instruction, the production plan is generated as described above. The ordering system 11
From 00, generation of a production plan that reflects the received new order information is also performed by picking the "initial plan" command 41 with the mouse.

On the other hand, after the production plan is generated, when the "problem analysis" command menu 40 of the command menus in FIG. 7 is picked with the mouse, the problem analysis instruction 19 of FIG. 1 is instructed. The problem analysis device 7 receives the problem analysis instruction 19 and inputs the produced production plan from the data storage device 11.

The problem analysis device 7 searches the contents of the production plan, and the start date of the earliest process is before the present date (that is, if the production start is not performed before the present date, the completion date of the product is determined). A list of items that are not satisfied) is created for each order number, the result 20 is output to the data input / output device 12, and the problem analysis result is displayed on the display device of the data input / output device 12.

At this time, among the externally procured parts, a list of items whose ordering date is before the current day point (that is, the item which cannot meet the production plan unless the order is placed before the present) is created. However, the result may be output to the data input / output device 12 and displayed.

FIG. 8 shows an output screen of the problem analysis result.

In FIG. 8, the problem section display table 42 has a horizontal axis indicating a period of a half month unit and a vertical axis indicating a product category.

Each matrix divided by the vertical and horizontal axes has a delivery date within the range represented by the horizontal axis, and the production start date or the order date of the externally procured parts in the corresponding item is earlier than the present date. If there is something that cannot be delivered on time, it is displayed in dark color. At that time, the number of cases included in the matrix as information to show the problem occurrence status,
The quantity, the number of delays (the number of products whose start date of the earliest process is before the current date), the maximum delay (the number of days from the earliest start date to the present), etc. are displayed.

Now, the planner can refer to the detailed information of the matrix where these problems occur by the following procedure.

Determination of Detailed Information Reference Matrix Pick a matrix for which detailed information is to be referred with the mouse. FIG. 8 shows that the matrix part of “period: March / upper, category: 2” is picked.

Insufficient inventory / Launch start Order list display Pick the "Order list" menu 44 from the command menu. By picking the "order list" menu, the start-delay order list 43 is displayed as detailed information. In the delayed start table 43, there is a stock shortage (the order date of the externally procured parts to be used is before the present date) or the start delay (the production start date is before the present date). For the product of the order number, the inventory shortage, the number of items that are delayed in the start (number of related items), the delivery date, and the delay / margin are displayed (details of the delay / margin will be described later).

On the other hand, when the "select" menu 45 of the command menu is picked after the detailed information reference matrix is determined in FIG. 8, the order number / date problem occurrence point display table 46 shown in FIG. 9 is displayed.

In FIG. 9, the note number / date-specific problem occurrence point display table 46 has the horizontal axis indicating the date and the vertical axis indicating the note number.

The displayed period corresponds to "period: March / upper, category: range of 2" shown in FIG.

Problem occurrence by note number / date In the problem occurrence point display table 46, the dark matrix portion indicates the problem occurrence point. As information for indicating the occurrence problem situation, the maximum delay and the product of the order number Regarding the item, the number of items for which the start of work has been delayed and there is a shortage of inventory is displayed.

Here, the detailed information of the matrix in which the problem occurs in the note number / date-specific problem occurrence point display table 46 can be referred to by the following procedure.

Determination of Detailed Information Reference Matrix A matrix for which detailed information is to be referred is picked up by the mouse. In Figure 6, "Period: 3/4, note number: 10
The "03" matrix has been picked.

Detailed Information Instruction Pick the “Details” menu 48 from the command menu. A detailed information list 47 is displayed by picking the “details” menu. In the detailed information list 47,
The product name, model, quantity, number of days behind the start (number of days from the start of manufacturing to the present), etc. of the specified order number are displayed.

By picking up the “item list” menu 49 instead of the “details” menu 48 for displaying the list of delayed items, the item list screen 50 shown in FIG. Displays the number of days late, the quantity, etc. of all the items that are late.

When the problem of the production plan is confirmed from the display of the problem point on the data input / output device 12 by the problem point analysis device 7 described above, the planner must adjust the production plan. .

The production plan can be adjusted on the display shown in FIG.

FIG. 11 shows the problem route display section 53, the production capacity display section 54, the completion date change menu 55, the alternative shop menu 56, the capacity adjustment menu 57, the MRP execution instruction menu 58, the work start order change menu 150, Production adjustment menu-151, plan deletion menu-156, adjustment execution menu-157, countermeasure proposal menu-93,
Production capacity change start time setting dial 59, production capacity change end time setting dial 60, production capacity setting dial 61
Etc.

The display of FIG. 11 is called by the following procedure, and the called problem route display portion 53 being displayed.
Displays the problem route. The route indicates the manufacturing process of the item in relation to the shop and the lead time.
The problem route is the route of the item selected as the countermeasure item among the items for which the start delay has occurred.

Selection of Countermeasure Item In adjusting the production plan, the target item (item in which inventory shortage, start delay has occurred) is selected. For example, in the inventory shortage / delayed item list 50 in FIG.
By picking the "end" button 52 with the mouse, the "partition plate" is selected as the target item.

Production Plan Adjustment Instruction Pick the “adjustment” menu 51 from the command menu on the output screen of FIG.

Problem Analysis As a result, the data input / output device 12 issues a problem analysis instruction 19. The problem analysis device 7 receives the problem analysis instruction 19 and outputs the production plan 2 from the data storage device 11.
Enter 1.

Further, the problem analysis device 7 obtains each shop used for manufacturing the countermeasure item selected in and its load condition, and outputs the result 20 to the data input / output device.

Problem Route Display The data input / output device 12 displays the problem analysis result 20 on the problem route display section 53 in a predetermined format.

The display format of the problem route display section 53 has the following features.

Only the shops related to the route of the countermeasure item are displayed.

The load status (work volume / production capacity) of each shop for each period is displayed in different colors according to its size.

The route of the countermeasure target item is shown on the display of the load status of each shop for each period. In FIG. 11, the problem route is shown by a bold line frame 80, and the shop 9
7,3,2,1 indicates that the item is manufactured. Further, one thick frame rectangle indicates a process in one shop, and the horizontal axis direction indicates the lead time of the process.

By configuring the problem route display section 53 in this way, the production planner can easily understand the problem route, and at the same time, regarding the problem of the work fee, the measure is taken from the place where the congestion degree is large. It becomes possible to easily make such a decision.

Now, in this state, "countermeasure proposal"
When the menu 93 is picked up, the data storage device 11
For the order number using countermeasure items, as the final judgment,
If the fact that a plan can be planned is stored by changing the production schedule of the order number that has not been assigned to the order, that effect is displayed in the area 95. Also, at this time,
As shown in FIG. 11, information about the order number stored in the data storage device 11 as the schedule change target order number may be displayed together with this order number. In addition, whether the amount of work or the amount of inventory is a problem is displayed together.

If it is stored as the final determination that there is a case where a production plan satisfying the production request corresponding to the order number cannot be drafted, that fact is displayed.

Also in this case, which of the work amount and the stock amount is the problem is also displayed.

The determination of the production plan from the aspects of the amount of work and the amount of inventory performed by the MRP expansion device 8, the work charge analysis device 27, and the production plan execution determination device 101 described above is performed when the production plan is generated. Instead, it may be performed based on the detailed production plan stored in the data storage device 11 when the countermeasure proposal menu 93 is picked up.

As a result, the production planner can obtain the guideline for the countermeasure for the countermeasure item, so the countermeasure is decided based on the guideline and the production plan is adjusted.

Now, the adjustment of the production plan is carried out by the completion date change menu 55, the alternative shop menu 56, the capacity adjustment menu 57, the MRP execution instruction menu 58, the work start order change menu 150, the production amount adjustment menu 151, and the plan. Use Delete Menu-156.

First, when the production planner decides to change the capacity of the shop as a countermeasure, the production plan is adjusted by the following procedure.

Selection of production capacity changing step After the step of changing the production capacity in the problem route in the problem route display portion 53 is picked with the mouse, the capacity adjustment menu 57 is picked. For example, shop in FIG.
Pick the part surrounded by the thick line in 3 with the mouse.

Display on the production capacity display section 54 Accordingly, the data input / output device 12 displays the load status and the production capacity of the process selected above in the format shown on the production capacity display section 54, as shown in FIG. . The production capacity display unit 54 includes a load status 62, a production capacity line 63, a production capacity change start point 64, a production capacity change open / close point 65, and a production capacity change target section frame 66.

Setting of production capacity change start / end point Production capacity change start point 64, production capacity change start point 6 and production capacity change end point 6 by picking the production capacity change start time setting dial 59 and the production capacity change end point setting dial 60 with the mouse.
Move 5 left and right. In the case of picking with a mouse, for example, in the case of a two-button mouse, when the left mouse button is picked, the production capacity change start / end point is moved to the left,
If you pick the right button, move to the right.

Production Capacity Change By picking the production capacity setting dial 61 with the mouse, the production capacity in the section between the production capacity change start point 64 and the production capacity change opening end point 65 is changed. In the case of picking with a mouse, for example, in the case of a two-button type mouse, if the left mouse button is picked, the production capacity line 63 is moved downward (production capacity is decreased), and if the right button is picked, production capacity is increased (production capacity). Increase).

After changing lead time / execution of MRP calculation, when the adjustment execution menu-157 is picked, the data input / output device 12 issues the production capacity adjustment instruction 15 to the production capacity adjusting device 4 based on the result of the production capacity change. . The production capacity adjustment device 4 sends the production capacity adjustment result and the MRP execution instruction 22 to the MRP control device 2. MRP controller 2
Regenerates only the production plan for the order number manufactured by the problem route including the selected process based on the production capacity adjustment result in cooperation with the MRP expansion device. That is, only the production plan is recalculated on the basis of the production plans related to the other order numbers, and the production plan is corrected. The modified production plan is stored in the data storage device 11. However, the production plans of all the order numbers may be regenerated based on the production capacity adjustment result. When modifying or generating this production plan, the MRP expansion device 8, the work amount analysis device 27, the production plan item determination device 10
1 again performs the above-described determination of the work amount and the inventory amount, and updates the determination content of the data storage device 11.

Changing the problem route display section The data input / output device 12 includes the data storage layer 11 and the MR.
The P execution result 21 is input and the production plan related to the countermeasure target item is corrected and displayed.

With the above, the production planner can change the production capacity by a simple operation, and at the same time, it is possible to confirm online how the change of the production capacity will affect the production plan. .

By the way, the display of the production capacity display section 54 of FIG. 12 may be configured as shown in FIG.

The lead time display section 90, the capacity increase button 91 and the capacity decrease button 92 of FIG. 13 are provided. In this case, the above-mentioned operation is different, which will be described.

[Setting of production capacity change start / end point] By picking the bar graph of the load status 62 with the left mouse button, the date is selected by picking the production capacity change start point 64 with the right mouse button. The production capacity change end point 65 is set to.

[Production Capacity Change] The production capacity in the section between the production capacity change start point 64 and the production capacity change end point 65 is changed by picking the capacity increase button 91 and the capacity decrease button 92 with the mouse.

Next, when the production planner decides to change the capacity of the shop as a countermeasure, the production plan is adjusted by the following procedure.

FIG. 14 shows a screen for changing the product completion date. The display screen of FIG. 14 is called by picking the completion date change mode switching menu 55 of FIG. 11 with the mouse.

On the screen for changing the product completion date, the delay / margin display section 68 is composed of a note number display 75, a margin display 76, a delay display 78, and a delay / margin bar graph 79.

In the delay / margin bar graph 79, the black portion between “current” and “start” indicates the number of days behind start,
The white part between "completion" and "delivery date" represents the number of spare days. Here, the "delivery date" is the delivery date answered by the customer, and the "completion" is the scheduled product completion date in the production plan. As described above, when a production plan is created, it is common to set a scheduled product completion date with a certain amount of customer delivery time.

Therefore, for a product which has a delay in starting work, it may be possible to eliminate the delay in starting work by bringing the scheduled completion date closer to the delivery date.

The change of the product completion date is executed by the following procedure.

Selection of completion date change order number When a plurality of problem routes are displayed, it is selected which order number product is to be changed in completion date. To select a note number, pick the note number change dial 73 with the mouse. In picking with a mouse, for example, in the case of a two-button mouse, when the left button of the mouse is picked, the note number is increased, and when the right button is picked, the note number is decreased. In FIG. 14, since only one problem route is displayed, the order number 1003 is the target for changing the completion date.

Change completion date Change the completion date by picking the change completion date dial 74 with the mouse. For example, in the case of a two-button mouse, if you pick the left button of the mouse, the completion date will be earlier (move the "Completion" display to the left), and if you select the right button, the completion date will be later ("Completion date". Move the display to the right).

The completion date may be changed by moving (dragging) the delay / margin bar graph 79 left and right while picking it up with the mouse.

MRP Calculation Execution When the adjustment execution menu-157 is picked up, the data input / output device 12 issues a completion date adjustment instruction to the completion date adjustment device 5 based on the completion date change result. Completion date adjustment device 5
Gives the completion date adjustment result and the MRP execution instruction 23 to the MRP control device 2. Based on the completion date adjustment result, the MRP control device 2 cooperates with the MRP development device to regenerate only the production plan of the order number manufactured by the problem route including the selected process. That is, with the production plans for other order numbers as a precondition, only the production plans for the selected order numbers are recalculated and the production plan is revised. The modified production plan is stored in the data storage device 11.
However, the completion schedule may be changed based on the completion date adjustment result, and the production plans for all the order numbers may be regenerated. When modifying or generating this production plan, the MRP expansion device 8, the work amount analysis device 27,
The production plan item determination device 101 again performs the determination in terms of the work amount and the inventory amount described above, and the data storage device 1
The contents of the judgment of 1 are updated.

Change of problem route / delay / margin display unit The data input / output device 12 inputs a new production plan from the data storage device 11 and corrects and displays the problem route / delay / margin display unit.

As described above, the production planner can change the completion date with a simple operation, and at the same time, can confirm online how the change of the product completion date affects the production plan. Become.

Next, when the production planner decides to change the shop as a countermeasure, the production plan is adjusted by the following procedure.

FIG. 15 shows a screen for changing the production shop.
The production shop change screen shown in FIG. 15 is called when the alternative shop mode switching menu 56 of FIG. 11 is picked.

In the alternative shop display portion 81 in the figure, when an arbitrary process in the problem route is selected, a group of alternative shops which can execute the work equivalent to the process and the lead time in each alternative shop. In addition, the number of days for improvement when adopting each alternative shop, that is, the number of days for shortening lead time is displayed.

That is, when an alternative shop exists in an arbitrary process of the problem route, there is a possibility that the delay in starting work can be resolved by adopting the alternative shop.

The production plan adjustment while changing the production shop is executed by the following procedure.

Selection of production shop change process In the problem route display portion 80, a process for changing the production shop is picked with the mouse. For example, the portion surrounded by the thick line of shop3 in FIG. 15 is picked with the mouse. When there is an alternative shop, the alternative shop display section 81 is displayed.

Further, the alternative shop is displayed in the problem route display portion 53 in the format as shown in FIG.

Alternative shop selection The alternative shop is selected by picking each shop name in the alternative shop display area 81 with the mouse.

MRP Calculation Execution When the adjustment execution menu-157 is picked, the data input / output device 12 issues an alternative shop adjustment instruction 17 to the alternative shop adjustment device 6 based on the alternative shop selection result. The alternative shop adjustment device 6 outputs the alternative shop adjustment result and the MRP execution instruction 24 to the MRP control device 2. Based on the alternative shop adjustment result, the MRP control device 2 cooperates with the MRP expansion device to regenerate only the production plan for the order number manufactured by the problem route including the selected process. That is, only the production plans for the countermeasure items are recalculated with the production plans for the other order numbers as a precondition, and the production plans are corrected. The modified production plan is stored in the data storage device 11. However,
The production plans of all the order numbers may be regenerated based on the alternative shop adjustment result. When the production plan is modified or generated, the MRP expansion device 8, the work amount analysis device 27, and the production plan item determination device 101 again perform the determination in terms of the work amount and the stock amount,
The contents of the judgment of the data storage device 11 are updated.

Change the problem route display section. The data input / output device 12 changes from the data storage device 11 to the MR.
The P execution result 21 is input, and the problem route after the alternative shop is adopted is corrected and displayed.

As described above, the production planner can change the production shop by a simple operation, and at the same time, can confirm online how the change of the production shop affects the production plan.

Next, when the production planner decides to change the capacity of the work start sequence as a countermeasure, the production plan is adjusted by the following procedure.

FIG. 16 shows a screen for changing the work start order.
The work start order change screen is called when the work start procedure change menu 150 is picked in FIG.

The start order change display portion 167 shown in FIG. 16 indicates the process corresponding to the process and the process to be performed within the period including the process when an arbitrary process in the problem route is selected. The items for inputting the work start order of the number, the completion date of the order number, and the setting of the start order are displayed.

Production plan adjustment while changing the work start order is executed by the following procedure.

Selection of work start change order number In the problem route display portion 53, a process for changing the work start order is picked with the mouse. For example, shop
Pick the part surrounded by the thick line in 3 with the mouse. As a result, in the format shown in the start order change display section 167,
Set the work order of the order number that generated the selected process, the work number that generated the process that should be performed within the period including the process, the completion date of the order, and the start sequence. Items to enter are displayed.

Change work start order The start order before and after the order for which the order is changed from the order number group of the products displayed on the change order display area 167 is input to the change order input item. For example, in FIG. 13, in order to set the order number 1005 of the starting order 3 to the starting order 2, the starting order 2 is input to the order input item.

MRP calculation execution The data input / output device 12 issues a work start order adjustment instruction 31 to the work start order adjustment device 33 based on the work start order change result. The work start order adjustment device 31 is M
The RP control device 2 is instructed of the work start order adjustment result and the MRP execution instruction 23. The MRP control device 2 cooperates with the MRP expanding device based on the work start sequence adjustment result so that the MRP control device 2 satisfies the work start sequence adjustment result. Regenerate only the production plan. That is, only the production plans for the countermeasure items are recalculated with the production plans for the other order numbers as a precondition, and the production plans are corrected. The modified production plan is stored in the data storage device 11. When modifying this production plan, the MRP expansion device 8,
The work amount analysis device 27 and the production plan item determination device 101 are
The determination of the work amount and the inventory amount described above is performed again, and the determination content of the data storage device 11 is updated.

Change of problem route display unit The data input / output device 12 inputs the new production plan generated from the data storage device 11, and the problem route display unit 16
6 is corrected and displayed.

As a result of the above,
It is possible to change the work start sequence with a simple operation, and at the same time, it is possible to confirm online how the change of the work start sequence affects the production plan.

Next, when the production planner decides to change the production quantity as a countermeasure, the production plan is adjusted by the following procedure.

FIG. 17 shows a screen for changing the production amount. FIG. 17
This display screen is called by picking the production amount adjustment menu 151 of FIG. 11 with the mouse.

In FIG. 17, when the production process adjustment display unit 177 selects an arbitrary process in the problem route, the order number that generated the process, the completion date and the production amount, the margin and the delay. Is displayed.

The production plan adjustment while changing the production amount is executed by the following procedure.

Selection of production amount adjustment process In the problem route display portion 53, the process for which the production amount is to be changed is picked with the mouse. For example, sho in FIG.
Pick the part surrounded by the thick line of p3 with the mouse. As a result, in the format shown in the production change display section 177,
The order number that generated the process, its completion date and production volume, margin and delay are displayed.

[Production amount change] The change amount is input to the production amount change amount item of the order number of which the production amount is to be changed from the product order number group displayed in the production amount change display portion 177. For example, in FIG. 17, in order to change the production amount of the order number 1003 from 15 to 10, the change amount of 10 is input in the change amount input item.

MRP Calculation Execution When the adjustment execution menu-157 is picked up, the data input / output device 12 commands the production amount adjustment instruction 34 to the production amount adjustment device 40 based on the production amount change result. The production amount adjusting device 40 sends the production amount adjusting result and the MR to the MRP control device 2.
The P execution instruction 39 is output. The MRP controller 2 controls the MRP controller 2 so as to satisfy the work start order adjustment result.
On the basis of the production amount adjustment result, regenerates only the production plan for the order number whose production amount has been changed, in cooperation with the MRP expansion device. That is, only the production plans for the countermeasure items are recalculated with the production plans for the other order numbers as a precondition, and the production plans are corrected. The modified production plan is stored in the data storage device 11. However, the completion schedule may be changed based on the production amount adjustment result, and the production plans may be regenerated for all the order numbers. When modifying or creating this production plan, the MRP
The expansion device 8, the work amount analysis device 27, and the production plan execution determination device 101 perform the above-described determination in terms of the work amount and the stock amount again, and update the content of the determination stored in the data storage device 11. .

Change Problem Route Display Unit The data input / output device 12 inputs the corrected production plan from the data storage device 11 and corrects and displays the problem route display unit 176.

As described above, the person in charge of production planning can change the production amount by a simple operation, and at the same time, can confirm online how the change of the production amount affects the production plan.

Next, when the production planner decides to delete the production plan of a certain order as a countermeasure, the production plan is adjusted by the following procedure.

FIG. 18 shows a screen for plan deletion. The display screen of FIG. 18 is called by picking the plan deletion menu-156 of FIG. 11 with the mouse.

In the plan deletion display portion 187 in the figure, the completion date and the production quantity, the margin and the delay, and the customer allocation status regarding the order number displayed in the problem route display portion 53 are displayed.

Production plan adjustment while deleting a plan is executed by the following procedure.

Selection of Plan Deletion Order Number When a plurality of problem routes are displayed, it is selected which order number product the plan is to be deleted from. To select a note number, pick the note number change dial 189 with the mouse. In picking with a mouse, for example, in the case of a two-button mouse, when the left mouse button is picked, the note number is increased, and when the right button is picked, the note number is decreased. In FIG. 18, since only one problem route is displayed, the order number 1003 is the target of plan deletion.

Plan deletion The plan deletion execution button is picked for the order number displayed in the plan deletion display area 187.

MRP Calculation Execution When the adjustment execution menu-157 is picked up, the data input / output device 12 issues a plan deletion instruction 34 to the plan deletion device 103 based on the plan deletion result. Plan deletion device 1
03 outputs the plan deletion result and the MRP execution instruction 39 to the MRP control device 2. Based on the plan deletion result, the MRP control device 2 deletes the production request information for the order number to be deleted from the completed schedule, and instructs the MRP expansion device 8 to generate a new production plan. The produced production plan is stored in the data storage device 11. Note that when the production plan is generated, the MRP expansion device 8, the work amount analysis device 27, and the production plan execution determination device 101 perform the above-described determination of the work amount and the stock amount again, and store the data. The contents of the judgment stored in the device 11 are updated.

Change Problem Route Display Unit The data input / output device 12 inputs a new production plan from the data storage device 11 and corrects and displays the problem route display unit 186.

As described above, the person in charge of production planning can delete a plan by a simple operation, and at the same time, can confirm online how the deletion of the plan affects the production plan.

In this way, when the problem analysis and the adjustment of the production plan are repeated and finally the production plan having no problem route can be made, the production planner makes the production planning system 100.
0, the ordering system 1100 is instructed to answer the requested delivery date as the delivery date if the planned completion date of the order number assigned to the order is before the requested delivery date, and the completion date of the order number assigned to the order is scheduled. If the date is after the requested delivery date, the customer will be instructed to respond to the contracted delivery date after that date.

The adjusted production plan is passed to the manufacturing system 1200 and executed.

As described above, according to the present embodiment, in the production plan, the production allocated to the order from the customer is prioritized over the production plan not allocated to the order.
It is possible to provide a production planning system capable of determining whether or not a delivery date required by a customer can be satisfied in consideration of a work amount and an inventory amount of a shop.

Further, in such a production planning system, it is suggested to the planner how to prioritize the production allocated to the order from the customer over the production plan not allocated to the order. can do.

That is, when the order quantity is larger than the quantity planned in the forecast production plan, it is possible to flexibly change the production plan so as to satisfy the order contents as much as possible.

[0196]

As described above, according to the present invention, even if the actual required number is larger than the planned amount, the planner can make the production plan as much as possible to satisfy the actual required number. It is possible to provide a production planning system that can support changes that can be easily made.

[Brief description of drawings]

FIG. 1 is a block diagram showing a configuration of a production planning system according to an embodiment of the present invention.

FIG. 2 is a flowchart showing a processing procedure of production plan generation processing according to an embodiment of the present invention.

FIG. 3 is a diagram showing a method of lead time calculation according to an embodiment of the present invention.

FIG. 4 is a diagram showing a change in production capacity according to an embodiment of the present invention.
It is a figure which shows the method of dead time calculation.

FIG. 5 is a diagram showing a method of determining the possibility of formulating an executable production plan that satisfies the contents of an order in consideration of the amount of work according to an embodiment of the present invention.

FIG. 6 is a diagram showing a method of determining the possibility of formulating an executable production plan that satisfies an order content in consideration of an inventory amount according to an embodiment of the present invention.

FIG. 7 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 8 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 9 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 10 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 11 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 12 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 13 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 14 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 15 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 16 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 17 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

FIG. 18 is a diagram showing one display screen in the graphic user interface of the production planning system according to the embodiment of the present invention.

[Explanation of symbols]

 1 Lead Time Calculation Device 2 MRP Control Device 3 Work Load Calculation Device 7 Problem Analysis Device 8 MRP Expansion Device 11 Data Storage Device 12 Data Input / Output Device 101 Production Planning Execution Judgment Device 1000 Production Planning System 1100 Ordering System 1200 Prospect Production Planning System

Claims (10)

[Claims] 1. A manufacturing system having a part of a manufacturing process for manufacturing a final item, the item being used as a part of the final item in the carried step, or a plurality of shops for producing the final item. Is a production planning system that generates a production plan for a final item that is scheduled to be completed in a completion schedule that specifies the completion schedule of the final item when it is required to supply the required number of final items at the required time. If there are more than the required number of final items that are scheduled to be completed before the specified required time and have not been allocated to other requirements, allocate them to the request, and if they do not exist, ,
Based on the allocation means that adds the completion schedule of the final item that satisfies the requirement to the completion schedule, and the work volume of each process generated by the production plan on each day corresponds to each day based on the completion schedule. In order not to exceed the capacity of the shop, the means for generating the production plan by sequentially advancing the work period of each process for manufacturing each final item from the planned completion date, and the production plan generated. , For each process, each day,
When the completed work amount obtained by accumulating the work amount required to manufacture all the items scheduled to be completed in the process on the relevant day is calculated, and the work amount allocated for each process on each day exceeds the capacity of the shop on that day. In order to reallocate the excess work amount to the previous day, the work amount included in each completed work amount is sequentially calculated from the latest completion date to the past from the corresponding planned completion date. For each process, if the work is allocated on the day before the current date, during the period when the work is re-allocated on the previous day, and the future is continuous from the current day. In addition, the total amount of work for producing the final item not allocated to the request and the item used as a part of the final item is more than the cumulative total of the amount of work allocated on the day before the current date. or not If it exists, the production plan that satisfies the completion schedule of the final item assigned to the requirement is changed by changing the production plan for the final item not assigned to the requirement. A production planning system, comprising: a production plan execution determining means for determining that there is a possibility of planning. 2. The production planning system according to claim 1, wherein the production planning execution determining means determines a date before the current date for each process when the work amount is assigned to the previous day. The final item that is not allocated to the request for each of the child periods that do not include the current date among the multiple child periods that divide the period in which the day when the work amount is reassigned from the present date toward the future And the cumulative amount of work to produce the items used as parts for the final item is calculated from the amount of work reassigned from the first day of the child period to the last day of the child period. It is determined whether or not there is more work than the reallocated work, and it is used as a part of the final item not allocated to the request and the final item for the child period including the current date. The cumulative amount of work to produce the item is
It is judged whether or not there is more than the work amount obtained by subtracting the work amount re-assigned from the next day from the work amount assigned on the day before the current date, on the last day of the child period concerned, and all children If it exists for a period, for the process concerned, by changing the production plan for the final item not allocated to the requirement, the production plan is drafted to meet the completion schedule of the final item allocated to the requirement. A production planning system characterized by determining that there is a possibility. 3. A manufacturing system having a part of a manufacturing process for manufacturing a final item, the item being used as a part of the final item in the carried step, or a plurality of shops for producing the final item. Is a production planning system that generates a production plan for a final item that is scheduled to be completed in a completion schedule that specifies the completion schedule of the final item when it is required to supply the required number of final items at the required time. If there are more than the required number of final items that are scheduled to be completed before the specified required time and have not been allocated to other requirements, this is allocated to the request, and if not,
Allocation means for adding the completion schedule of the final item that satisfies the requirement to the completion schedule, means for generating a production plan based on the completion schedule, and the inventory quantity of the procurement item that is an item procured from outside. And a means for managing the planned inventory quantity, and for each procured item, the procured item's procured item will be If the required amount of each day in the production plan exceeds the inventory quantity and the planned inventory quantity on the corresponding day, the request is allocated on any day during the period required to procure the procurement item from the outside. Required to manufacture only the final item
Based on the generated production plan, determine whether the daily requirement of the procured item exceeds the inventory quantity and the planned inventory quantity on the corresponding day. Production plan execution determining means for determining that there is a possibility of drafting a production plan that satisfies the completion schedule of the final item assigned to the request by changing the production plan for the final item not assigned to the request A production planning system characterized by having. 4. An item used as a part of the final item in a part of a manufacturing process for manufacturing the final item based on a completion schedule that defines the completion schedule of the final item. Alternatively, a production planning system for producing a production plan of a manufacturing system having a plurality of shops for producing the final item, which comprises an allocation means, a requirement expansion means, a work amount calculation means, and a lead time calculation means. And a production plan execution determination means, wherein the allocation means is completed in a completion schedule that defines the completion schedule of the final item when required to supply the final item in the required number and at the required time. If there are more than the required number of final items that are scheduled to be completed before the specified required time and have not been allocated to other requirements, check these items. It is allocated to the requirement, and if it does not exist, the completion schedule of the final item that satisfies the requirement is added to the completed schedule, and the required amount developing means is manufactured in each step to satisfy the completed schedule. , The required amount of each item and the planned completion date of the item in the relevant process are calculated for each shop, and the work amount calculating means manufactures all the items of the expected completion date for each expected date of each process. In order to obtain the completed work amount by accumulating the work amount required for the above, the lead time calculation means, for each process, when the work amount allocated on each day exceeds the capacity of the shop on that day, Allocate the amount of work included in each completed work amount in order from the latest scheduled completion date to the past from the corresponding planned completion date to each day, so that the work amount is reassigned to the previous day Based on the earliest date to which the work amount included in the completed work amount is assigned and the lead time for manufacturing one item, the lead time for each item on each scheduled completion date is obtained, The production plan execution determination means, when the work amount is assigned to the day before the current date for each process, the date when the work amount is reassigned by the lead time calculation means to the previous day is the current date. The cumulative amount of work for producing the final item that is not allocated to the requirement and the item used as a part of the final item during the continuous period toward the future is the amount of work assigned before the period. It is determined whether there is more than the cumulative total of
Regarding this process, it is judged that there is a possibility of drafting a production plan that satisfies the completion schedule of the final item assigned to the requirement by changing the production plan for the final item not assigned to the requirement. The required amount developing means further sets a scheduled completion date for the final item in accordance with the completion schedule defined in the completion schedule, and the scheduled completion date and the lead time calculation and measurement means read the final item for the final item. From the dead time, the start date for the final item is calculated, and for items other than the final item, the start date for the process next to the process for producing the item is the scheduled completion date, and the scheduled completion date and the item -A production planning system characterized in that the start date of the item is obtained from the lead time obtained by the dead time calculating and measuring means. 5. The production planning system according to claim 4, wherein the production planning execution determining means determines, for each process, on a day before the current date, when a work amount is assigned, on the previous day. The final item that is not allocated to the request for each of the child periods that do not include the current date among the multiple child periods that divide the period in which the day when the work amount is reassigned from the present date toward the future And the cumulative amount of work to produce the items used as parts for the final item is calculated from the amount of work reassigned from the first day of the child period to the last day of the child period. It is determined whether or not there is more work than the reallocated work, and it is used as a part of the final item not allocated to the request and the final item for the child period including the current date. The cumulative amount of work to produce the item is the work that is allocated on the day before the current date, minus the work that was reallocated from the next day on the last day of the child period. If it exists for all the child periods, it is allocated to the request by changing the production plan for the final item not allocated to the request. A production planning system characterized by determining that there is a possibility of drafting a production plan that meets the completion schedule of the final item. 6. The production planning system according to claim 1, 2, 4, or 5, wherein the production planning execution determination means further changes the production planning for the final item not allocated to the request. According to the above, the final item assigned to the requirement manufactured by only the process determined to have the possibility of drafting a production plan that satisfies the requirement of the final item assigned to the requirement is assigned to the requirement. A production planning system characterized by determining that there is a possibility of drafting a production plan that satisfies the completion schedule by changing the production plan for the final item that does not exist. 7. The production planning system according to claim 1, wherein the production planning execution determining means is assigned to the request by changing a production plan for a final item not assigned to the request. The determination result that there is a possibility of drafting a production plan that meets the completion schedule of the final item, and the identification of the production plan of the final item that has generated the workload during the period and is not allocated to the request The production planning system is capable of formulating a production plan that satisfies the completion schedule of the final item assigned to the requirement by changing the production plan for the final item not assigned to the requirement. And a method for displaying the identification of the process determined to have the property in association with the stored determination result and the identification of the production plan of the final item. System. 8. The production planning system according to claim 3, wherein the production planning execution determination means is assigned to the request by changing a production plan for a final item not assigned to the request. The decision result that there is a possibility of drafting a production plan that meets the completion schedule of the final item, and the production plan of the final item that requires procurement parts during the period and is not allocated to the request. And storing the identification, the production planning system modifies the production plan for the final item not assigned to the requirement to create a production plan that meets the completion schedule of the final item assigned to the requirement. It is characterized by having means for displaying the identification of the procured item determined to be possible in association with the stored identification of the production plan of the final item. Production planning system. 9. A manufacturing system having a part of a manufacturing process for manufacturing a final item, the item being used as a part of the final item in the carried step, or a plurality of shops for producing the final item. Of the final product scheduled to be completed in the completion schedule that defines the completion schedule of the final product when it is required to supply the required number of final products at the required time. In the case where there is more than the required number of final items that are scheduled to be completed before the specified required period and have not been allocated to other requirements, this is allocated to the request, and if they do not exist,
The completion schedule of the final item that satisfies the requirement is added to the completion schedule, and the amount of work of each process generated by the production plan on each day is based on the completion schedule with the completion schedule added. The production schedule is generated by sequentially advancing the work period of each process for manufacturing each final item so that it does not exceed the capacity of the corresponding shop of Therefore, for each process, for each day,
When the completed work amount obtained by accumulating the work amount required to manufacture all the items scheduled to be completed in the process on the relevant day is calculated, and the work amount allocated for each process on each day exceeds the capacity of the shop on that day. In order to reallocate the excess work amount to the previous day, the work amount included in each completed work amount is sequentially calculated from the latest completion date to the past from the corresponding planned completion date. For each process, if the work is allocated on the day before the current day, during the period when the day when the work is re-allocated on the day before is continuous from the current day to the future, Whether the cumulative amount of work for producing the final item not allocated to the request and the item used as a part of the final item is greater than or equal to the cumulative amount of work assigned to the day before the current date. Judge , If it exists, by changing the production plan for the final item that is not assigned to the requirement for the process, it is possible to formulate a production plan that meets the completion schedule of the final item assigned to the requirement. A method for evaluating a production plan, characterized by determining that there is a property. 10. A manufacturing system having a part of a manufacturing process for manufacturing a final item, an item used as a part of the final item in the carried step, or a plurality of shops for producing the final item. Is a method of evaluating the production plan of, which manages the inventory quantity and planned inventory quantity of procurement items that are items to be procured from the outside, and when it is required to supply the required number of final items at the required time, Among the final items to be completed in the completion schedule that specifies the completion schedule of the final item, there are more than the required number of final items that are scheduled to be completed before the specified required time and are not allocated to other requirements. If so, assign this to the request; if not,
The completion schedule of the final item that satisfies the requirement is added to the completion schedule, the production plan is generated based on the completion schedule to which the completion schedule is added, and from the generated production plan from the current date, In any day during the period required to procure procured items from the outside to realize the production plan, the required amount on each day of the production plan for the procured items is the inventory amount and inventory on the corresponding day. Each of the procured items required to manufacture only the final item allocated to the requirement on any day during the period required to procure the procured items from the outside when the planned amount is exceeded. By determining whether the daily requirement does not exceed the inventory quantity and the planned inventory quantity on the corresponding day, and if not, by changing the production plan for the final item not allocated to the request, Evaluation method of production planning, characterized in that it determined that there is a possibility of the planning of the production plan to meet the completion schedule of the end item that is reserved to the serial request.