JPH08147358A - Device for preparing order plan of raw material - Google Patents

Abstract

PURPOSE: To prepare the ordering plan of raw material necessary for manufacture based on a production schedule. CONSTITUTION: Based on raw material necessary quantity data by the day, which is calculated by a raw material necessary quantity calculation part 3 and basic data of each raw material stored in a basic data storage part 1, a stock simulation part 4 executes the processing of obtaining remaining total stock by subtracting the necessary quantity of raw material for the day from the total stock of raw material and when the remaining total stock becomes less than an ordering point on an optional day, the part 4 prepares the ordering plan for issuing order by just an ordering quantity obtained based on an ordering lot on a day going back by the part of an ordering read time from the optional day and processing of adding ware housing quantity to the remaining total stock at the optional day by considering that raw material is wavehoused by just the ordering quantity on the optional day. An ordering plan preparing part 5 prepares ordering plan data obtained by arranging the ordering plans prepared at the simulation process of the total stock by the raw material.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention, when creating a production plan for a production line by make-to-stock production, calculates the required amount of raw materials necessary for the plan from the produced production plan,
The present invention relates to a raw material order planning device that provides information necessary for ordering raw materials by performing a raw material inventory simulation.

[0002]

2. Description of the Related Art An apparatus for displaying and evaluating the inventory quantity of a product or an apparatus for creating a production plan by utilizing an inventory simulation is disclosed in, for example, Japanese Patent Laid-Open No. 5-225
Various proposals have been made in the past, as can be seen in the production plan creation apparatus of Japanese Patent Publication No. 198.

This conventional production planning apparatus is based on a shipment forecast and a selection unit for selecting a main product to be subject to accelerated production, and a calculated value of the difference between the shipment forecast of all items and the production capacity. It is equipped with a production planning section that plans the production volume of the main products, the production start time of the production, and the inventory.
In addition to these configurations, a production simulation unit that obtains a production load by a production simulation based on shipping prediction and a forward production amount correction unit that corrects the previously produced advance production amount are provided.

The production plan of the product created by such a production plan creating apparatus is a production plan that does not cause excess inventory or inventory shortage and has a high operating rate.

[0005]

The production plan created in this manner is just a production plan for a product, and no consideration is given to raw materials for producing the product. In other words, if the production plan gives a production instruction but the raw materials have not been procured, adjustment work such as changing the production date or reducing the production volume is required. There was a problem that we had to review it.

The present invention was devised to solve the above problems, and an object thereof is to provide a raw material ordering plan preparation apparatus for preparing an ordering plan for raw materials necessary for production from the result of a prepared production plan. To provide.

[0007]

In order to solve the above-mentioned problems, the raw material ordering plan preparing apparatus according to the present invention has a stock amount of raw materials, an ordering point, and a replenishment set based on data such as past shipment records. A basic data storage unit that stores basic data such as points, order lots, and order lead time for each raw material, and the type of raw material used and the raw material development data of the required amount per unit of the raw material is stored for each product number. In accordance with the production plan data created based on the data storage unit, the sales plan in the predetermined year and the past shipment results, the production is performed based on the raw material development data for each production product number stored in the development data storage unit. A raw material requirement calculation unit that calculates the required raw material requirement on a daily basis, and raw material requirement data for each day calculated by this raw material requirement calculation unit,
Based on the basic data for each raw material stored in the basic data storage unit, for the entire period of the order planning period for the raw material, subtract the required amount of the raw material of the day from the raw material inventory amount to obtain the remaining inventory amount. In addition to performing the required processing, when the remaining stock quantity becomes less than or equal to the ordering point on any day within the order planning target period, only the order quantity required based on the order lot is placed and the order lead time from the any day. An inventory simulation that creates an ordering plan to place an order on a date that goes backwards, and performs processing to add the receipt amount to the remaining stock amount on the arbitrary day, assuming that the raw material is received by the ordered amount on the arbitrary day. Section and this inventory simulation section performs a simulation of the inventory quantity for all target raw materials and The ordering plan produced Te and a configuration in which a purchase order plan generator summarized for each raw material for the ordering the time horizon.

[0008]

[Function] The basic data storage unit stores, for each raw material, basic data such as the stock amount of the raw material, the order point, the replenishment point, the order lot, and the order lead time, which are set based on the data such as the past shipping records. In the expanded data storage section,
Raw material development data of the type of raw material used and the required amount per unit of the raw material is stored for each production item number.

Then, in the raw material requirement calculation unit, the raw material development data for each production item number stored in the development data storage unit according to the production plan data created based on the sales plan in the predetermined year and the past shipment results. Based on, the raw material requirements for production are calculated on a daily basis.

In the stock simulation section, based on the daily raw material requirement data calculated by the raw material requirement calculation section and the basic data for each raw material stored in the basic data storage section, the raw material order planning target For the entire period, a process of obtaining the remaining inventory amount by subtracting the required amount of raw material of the day from the inventory amount of raw material is performed. And
In the process of this process, when the remaining stock quantity becomes less than the ordering point on any day within the order planning period, only the order quantity calculated based on the order lot, and the order lead time from any day Create an order plan to place an order on a retroactive day. Then, assuming that the raw materials have been stored by the ordered quantity on any day, the stocked quantity is added to the remaining stock quantity on any day.

The ordering plan preparing section simulates the stock quantity by the stock simulating section for all target raw materials, and summarizes the ordering plan prepared in the simulation process for each raw material for the order planning target period. Create a raw material ordering plan.

The created raw material ordering plan can be displayed on a display screen and can be set by a printer or the like. Further, the operator can correct the plan while watching the order plan displayed on the display screen.

[0013]

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

FIG. 1 shows the electrical construction of the raw material order planning system according to the present invention.

In the figure, the output of the development data storage unit 2 in which the raw material development data of the type of raw material used and the required amount per unit of the raw material is stored for each production part number is the raw material required amount for production. It is led to the raw material required amount calculation unit 3 which is calculated for each day, and the output of the raw material required amount calculation unit 3 is led to the inventory simulation unit 4 which performs the raw material inventory simulation. In addition, the raw material requirement calculation unit 3 is guided by production plan data created based on a sales plan for a predetermined year and past shipment results.

In addition, the stock simulation section 4 provides basic data for each raw material such as stock amount of raw material, order point, replenishment point, order lot, and order lead time, which are set based on data such as past shipment records. The output of the stored basic data storage unit 1 is guided, and the output of the inventory simulation unit 4 is guided to the order plan creation unit 5 that creates a raw material order plan. The output of the order plan creation unit 5 is connected to a display device, a printer, or the like (not shown) so that the created order plan table can be displayed on the display screen or printed out.

Further, the output of the input unit 6 equipped with a keyboard or the like is led to the order plan creation unit 5, and the operator can correct the plan while looking at the order plan displayed on the display screen. It is composed.

The raw material requirement calculation unit 3 converts the raw material development data for each production part number stored in the development data storage unit according to the production plan data created based on the sales plan in the predetermined year and the past shipment results. Based on this, it is a block that calculates the raw material requirements for production on a daily basis.

The stock simulation section 4 orders raw materials based on the daily raw material requirement data calculated by the raw material requirement calculation section 3 and the basic data for each raw material stored in the basic data storage section 1. For the entire planning period, processing is performed to subtract the required amount of the raw material for the current day from the raw material inventory amount to obtain the remaining inventory amount. And
In the process of this process, when the remaining stock quantity becomes less than the ordering point on any day within the order planning period, only the order quantity calculated based on the order lot, and the order lead time from any day Create an order plan to place an order on a retroactive day. Then, it is a block that performs processing for adding the warehousing amount to the remaining stock amount on any day, assuming that the raw material is stored by the ordered amount on any day.

The ordering plan preparing section 5 simulates the stock quantity by the stock simulating section 4 for all the target raw materials, and the ordering plan created in the simulation process for each raw material for the ordering plan target period. Collectively, it is a block that creates an ordering plan for raw materials.

FIG. 2 shows an example of each data of the stock amount of raw materials, the order point, the replenishment point, the order lot and the order lead time stored in the basic data storage unit 1. These data are set based on, for example, past shipping record data.

Here, the stock amount is updated when the raw materials are used and delivered, and in FIG. 2, the initial stock amount of each of the raw materials a to e (that is, the stock on the first day of the order planning target period). Amount).

The ordering point is the stock quantity which serves as a standard for judging that the product should be produced when the stock quantity falls to a certain level. Raw materials having a quantity lower than the order point are listed up as an order part number. It This ordering point is set in consideration of past usage records.

The replenishment point is the upper limit value of the order quantity when the part number of the raw material is ordered. In other words, the order quantity is the quantity until the replenishment point is reached. This supplement point is also set in consideration of past usage records.

The order lot is the minimum unit for determining the order quantity, and the actual order quantity is rounded to an integral multiple of the lot size. This process is hereinafter referred to as lot rounding.

The order lead time is the period from when the order is issued until the product is actually stored.

That is, looking at, for example, the raw material a in FIG. 2, the stock quantity on the first day of the order planning target period is 60, the order point for issuing a production instruction is 50, and the replenishment point which is the upper limit value of the order quantity is 100, The order lot is 30 and the order lead time is 2 days. FIG. 3 shows an example of raw material development data stored in the development data storage unit 2, in which the types of raw materials used and the raw material development data of the required amount per unit of the raw materials are production product numbers A to E. It is stored for each. These data are set based on, for example, past shipping record data.

That is, referring to, for example, the product number A in FIG. 3, the raw materials used for the product number A are the product number a and the product number c, and the required amount per unit of the product number a is 1, and the required amount per unit of the product number c. Is 10.

Further, FIG. 4 shows an example of production plan data created based on a sales plan for a predetermined year and past shipping records.

For example, looking at the product number A, the first day of the order planning target period is 10, 5th day, 10th and 7th day.
It is planned to produce 10 on the 0th and 10th days and 10 on the 12th day, respectively.

Next, the operation of the order plan creating apparatus having the above configuration will be described.

In this embodiment, the target period of the order plan is 12
I'm going to the day.

First, in the raw material required amount calculation unit 3, the data shown in FIG.
Based on the production plan data shown in, the raw material requirement for production is calculated for each day.

From the data shown in FIG. 4, for example, on the first day of the production planning data, the product number A is 10, and the product number D is 5.
It is planned to produce each. Then, from the data shown in FIG. 3, for the production part number A, the raw material part number a is 1 and the raw material part number c is used, and for the production part number D, the raw material part number b is 1, and the raw material part number c is used. To produce.

Therefore, looking at the first day (the first day) of the order planning target period, 10 raw material parts a are required,
The raw material part number b is required to be 5, the raw material part number c is required to be 150, and the other part numbers d and e are unnecessary (see FIG. 5).

The raw material required amount calculating unit 3 obtains the raw material required amount data shown in FIG. 5 by sequentially performing such calculation processing on the second day, the third day, ... The 12th day.

Then, the raw material required amount data is given to the inventory simulation section 4.

Based on the raw material required amount data shown in FIG. 5 and the basic data for each raw material a to e shown in FIG. For the entire period, processing is performed to subtract the required amount of raw material on the day from the amount of raw material inventory to obtain the remaining inventory amount. In the process of this process, when the remaining stock quantity falls below the ordering point on any day within the order planning target period, only the order quantity calculated based on the order lot is placed on the order lead from any day. Create an ordering plan to place an order on a day back in time. Then, assuming that the raw materials have been stored by the ordered quantity on any day, the stocked quantity is added to the remaining stock quantity on any day. The inventory simulation unit 4 obtains the simulation result shown in FIG. 6 by performing such arithmetic processing for all raw material product numbers a to e.

That is, looking at the raw material part number a,
The inventory quantity on the first day is 60. Since the raw material requirement on the first day is 10, this raw material requirement is 10
The quantity (50) obtained by subtracting the stock quantity 60 from the stock quantity 60 is 2
The inventory quantity for the first day. Since the stock quantity 50 on the second day is not lower than the order point 50 of the raw material part number a, an order plan is not created at this point.

Next, since the raw material required amount on the second day is 5, the raw material required amount 5 is set as the delivery amount, and the amount (45) subtracted from the inventory amount 50 is set as the inventory amount on the third day. Since the stock quantity 45 on the third day is lower than the order point 50 of the raw material part number a, the order plan is created at this point.

That is, in order to replenish up to 100, which is the replenishment point, it is necessary to store 55 (100-45), but since the order lot of the raw material part number a is 30,
The lot is rounded and the storage amount is set to 60. Therefore, the actual inventory amount is 10 which is the inventory amount 45 plus the receipt amount 60.
It becomes 5. Also, the ordering lead time for raw material part number a is 2
Since it is a day, the ordering plan will be decided as the ordering quantity 60 on the first day, which is two days before the third day.

Next, since the required raw material amount on the 4th day is 5, the raw material required amount 5 is used as the delivery amount, and the stock amount 105
The quantity (100) subtracted from is the stock quantity on the 5th day. Since the stock amount 100 on the fifth day is not lower than the order point 50 of the raw material part number a, the order plan is not created at this point.

Next, since the raw material requirement on the 5th day is 10, the raw material requirement 10 is used as the delivery quantity, and the stock amount 1
The quantity (90) subtracted from 00 is the stock quantity on the 6th day. 6
Since the stock amount 90 on the day is not lower than the order point 50 of the raw material part number a, the order plan is not created at this point.

Next, since the raw material required amount on the 7th day is 20, the raw material required amount 20 is set as the delivery amount, and the stock amount 9
The quantity (70) subtracted from 0 is the stock quantity on the 8th day. Since the stock amount 70 on the 8th day is not lower than the order point 50 of the raw material part number a, an order plan is not created at this point.

Next, since the raw material required amount on the 10th day is 15, the raw material required amount 15 is set as the delivery amount, and the amount (55) subtracted from the inventory amount 70 is set as the inventory amount on the 11th day.
Since the stock amount 55 on the 11th day is not lower than the order point 50 of the raw material part number a, an order plan is not created at this point.

Next, since the raw material required amount on the 12th day is 10, the raw material required amount 10 is set as the delivery amount, and the amount (45) subtracted from the inventory amount 55 is set as the inventory amount on the 13th day (illustrated. Omitted). Inventory quantity 45 on the 13th day is raw material part number a
Since the order point 50 is less than the order point 50, the order plan is created at this point.

That is, in order to replenish up to 100, which is the replenishment point, it is necessary to store 55 (100-45), but since the order lot of the raw material part number a is 30,
The lot is rounded and the planned storage amount is set to 60. Therefore, the actual inventory amount is 1 plus the inventory amount 45 plus the receipt amount 60.
It will be 05. Further, since the order lead time for the raw material part number a is 2 days, the order will be fixed as the order quantity 60 on the 10th day, which is two days before the 12th day.

In this way, the simulation for the raw material part number a is completed.

The stock simulation section 4 performs the same simulation as the above-mentioned raw material part number a for the other raw material part numbers b to e to obtain the simulation results shown in FIGS. 7 to 10.

In the order planning section 5, the raw materials a to a are obtained based on the simulation results of the raw material numbers a to e shown in FIGS.
An ordering plan table (FIG. 11) is prepared in which the ordering plan of e is summarized for each raw material for the period of the ordering plan.

That is, FIG. 11 is a table in which only the items of the order date and the ordered quantity of order of the simulation results of FIGS. 6 to 10 are taken out and summarized.

In other words, for the raw material part number a, 60 are planned to be ordered on the first day 60 and on the 10th day, and for the raw material part number b, 60 are planned on the first day and 80 on the seventh day. The raw material number c is 3
It is planned to place 300 orders on the 3rd day, 300 orders on the 7th day, and 300 orders on the 12th day. For raw material product number d, 300 orders on the 3rd day, 450 orders on the 6th day, and 300 orders on the 9th day. For the raw material part number e, 300 are planned to be ordered on the third day.

The order planning table created in this way is
It can be displayed on a display screen (not shown) and can be launched from a printer (not shown).

The order plan table displayed on the display screen can be modified by the operator. In the case of correction, an arbitrary part of the order planning table is corrected by operating the keyboard of the input unit 6, for example.

For example, in the ordering plan table shown in FIG. 11, 3
On the day, an order is issued for each of the raw material product numbers c, d, and e of 300, but it may not be possible to order three product numbers at the same time due to restrictions such as vehicle allocation. Therefore, in such a case, a correction such as shifting one of the orders back and forth or reducing the order quantity is added. The determination as to whether or not such a correction is necessary can be made more appropriately and accurately by displaying the order plan on the display screen.

In the above embodiment, the period for which the order is planned is 12 days.
It can be set to an arbitrary unit such as a unit of months.

[0057]

The raw material order planning apparatus according to the present invention calculates the raw material required amount for production on a daily basis based on the raw material development data for each production part number according to the production planning data. And the raw material requirement data for each day and the basic data for each raw material, the remaining stock amount is subtracted from the raw material inventory amount for the entire period of the raw material order planning period When the remaining stock quantity is below the ordering point on any day within the order planning period, only the order quantity calculated based on the order lot will be used for the order lead time from any day. There is a process to create an ordering plan to place an order on a retroactive day, and to add the stocked amount to the remaining inventory on any day, assuming that the raw material is stored in the quantity ordered on that day. And a simulation unit, a simulation of the inventory amount of this stock simulation unit,
In addition to carrying out all the target raw materials, the ordering plan created in this simulation process has an ordering plan creation section that summarizes the ordering target period for each raw material. It is possible to give instructions, and the effect of reducing inventory is improved.

[Brief description of drawings]

FIG. 1 is a block diagram showing an electrical configuration of a raw material ordering plan creation device according to the present invention.

FIG. 2 is a table showing an example of each data of stock amounts of raw materials, order points, supplement points, order lots, and order lead times stored in a basic data storage unit.

FIG. 3 is a table showing an example of raw material development data stored in a development data storage unit.

FIG. 4 is a table showing an example of production planning data created based on a predetermined year and past shipping results.

FIG. 5 is a table showing an example of raw material required amount data.

FIG. 6 is a table showing simulation results for raw material part number a.

FIG. 7 is a table showing simulation results for raw material part number b.

FIG. 8 is a table showing simulation results for raw material part number c.

FIG. 9 is a table showing simulation results for raw material part number d.

FIG. 10 is a table showing simulation results for raw material part number e.

FIG. 11 is a table showing an ordering plan obtained by inventory simulation.

[Explanation of symbols]

 1 Basic data storage 2 Expanded data storage 3 Raw material requirement calculation 4 Inventory simulation 5 Order plan creation 6 Input

[Procedure amendment]

[Submission date] April 11, 1995

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] Brief description of the drawing

[Correction method] Change

[Correction content]

[Brief description of drawings]

FIG. 1 is a block diagram showing an electrical configuration of a raw material ordering plan creation device according to the present invention.

FIG. 2 is a table showing an example of each data of stock amounts of raw materials, order points, supplement points, order lots, and order lead times stored in a basic data storage unit.

FIG. 3 is a chart showing an example of raw material development data stored in a development data storage unit.

FIG. 4 is a chart showing an example of production plan data created based on a predetermined year and past shipment results.

FIG. 5 is a chart showing an example of raw material required amount data.

FIG. 6 is a table showing simulation results for raw material part number a.

FIG. 7 is a chart showing simulation results for raw material part number b.

FIG. 8 is a chart showing simulation results for raw material part number c.

FIG. 9 is a table showing simulation results for raw material part number d.

FIG. 10 is a table showing simulation results for raw material part number e.

FIG. 11 is a chart showing an ordering plan obtained by an inventory simulation.

[Explanation of reference numerals] 1 basic data storage unit 2 expanded data storage unit 3 raw material required mass production output unit 4 inventory simulation unit 5 order plan creation unit 6 input unit

Claims (1)

[Claims] 1. A basic data storage unit for storing, for each raw material, basic data such as stock amount of raw materials, order points, replenishment points, order lots, and order lead times set based on data such as past shipment records. , A development data storage unit that stores the raw material development data of each type of raw material used and the required amount per unit of the raw material for each production part number, and the production created based on the sales plan in the predetermined year and the past shipment record A raw material requirement calculation unit that calculates the raw material requirement amount required for production on a daily basis based on the raw material development data for each production item number stored in the development data storage unit according to the plan data, and the raw material requirement amount calculation unit Based on the daily raw material requirement data calculated by and the basic data for each raw material stored in the basic data storage unit, the entire period of the raw material order planning period For the above, the processing is performed to subtract the required amount of the raw material on the day from the raw material inventory amount to obtain the remaining inventory amount, and the remaining inventory amount becomes the ordering point or less on any day within the order planning period. In this case, an ordering plan is created in which an ordering amount obtained based on the ordering lot is placed on a day traced back by the ordering lead time from the arbitrary day, and the raw material is stored in the ordered quantity on the arbitrary day. Assuming that, in addition to performing a simulation of the inventory amount by the inventory simulation unit that performs the process of adding the received amount to the remaining inventory amount on the arbitrary day and all the target raw materials by this inventory simulation unit, An ordering plan creating unit is provided for collecting the created ordering plan for each raw material for the ordering plan target period. Raw materials of ordering planning apparatus, characterized in that.