JPH08235256A - Reference production planning device - Google Patents

Abstract

PURPOSE: To provide a simple reference production planning device for which production ability in the manufacture process of a product and lead time are considered based on order taking information, a reference production schedule, a plan for material requirement and inventory information. CONSTITUTION: This reference production planning device 10 plans the production execution plan 5 of the product by an item information file 20 provided with a manufacture order file, a 1-level component shipping file, a 1-level component inventory file and a product master and the process procedure information file 30 of the manufacture process based on a sales plan system 1 for outputting received orders, the reference production schedule 2 for scheduling the received orders, a material requirement plan 3 for generating the manufacture order file of the product and the 1-level component shipping file of the components of the product from the reference production schedule 2 and the inventory information 4 provided with a 1-level component inventory file for indicating the inventory states of the components.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for making a production plan, and more particularly to a standard production plan making apparatus for making a production plan based on a simple rough process master determined from the lead time of each process of production and the producible quantity. Regarding

[0002]

2. Description of the Related Art Conventional production planning involves making a production plan based on sales information and past statistical data, and determining whether or not it can be carried out as a post-planning process by considering production capacity and other factors. ing. Also, many production plans are drafted at the work implementation level based on detailed data such as factories.
Therefore, there is a method of formulating a complicated determinant and formulating a plan by obtaining a solution from the formula. However, in the industrial world, the planning of work implementation level has begun to be considered considerably, but it is often the case that the order production and sales information lead the production of the standard production plan.

According to Japanese Patent Laid-Open No. 4-31285,
Disclosed is a production scheduling device that creates a production schedule by a heap graph for a factory calendar based on load forecasts and limited express item forecasts in a production plant, and flattens the heap graph by matching production quantity and production capacity. In the production scheduling device,
Since the focus is on aligning the factory calendar with the production schedule, the constraints on lead time and production capacity at the component level of the product are not reflected in the planning.

[0004]

In the conventional standard production planning described above, a heap of load graphs is created based on sales information, and the graphs are simply leveled to match the production capacity. . Moreover, the production planning does not take into consideration the production possibility check from the parts inventory of the product to the manufacturing process, the outsourcing and the load of the manufacturing process. In addition, even if the possibility of production and the process are taken into consideration, the information on the manufacturing process is extremely detailed, such as the procurement lead time, the manufacturing lead time, and the setup time. Data that cannot be requested may be requested. In order to create detailed data of the manufacturing process and make a production plan, there are many problems such as various kinds of data and complicated constraints and work that are difficult to systemize, and conventional systems are not effective in system construction and operation.

[0005]

An object of the present invention is to provide a simple standard in consideration of a manufacturing process of a product, a production capacity and a lead time based on an order order, a standard production schedule plan, a material requirement plan and inventory information. Provide a production planning device.

Therefore, the standard production planning apparatus for formulating a simple production execution plan for the ordered product is based on the ordered order, the standard production schedule plan and the material requirement plan acquired from the sales planning system of the present invention. Rough cut scheduling section that formulates a standard production plan that adjusts the production capacity of the production process based on the item information including information on the production process and required parts inventory and delivery of the product, and the production of each product And a rough process design section that creates process procedure information including a rough process master indicating a total lead time and a total production capacity of all processes. In addition, the item information is a manufacturing order file that stores a manufacturing order record that is obtained by classifying and collecting the order orders for each ordered product and for each bucket corresponding to the delivery date, and one level that indicates the one-rank lower order component that constitutes each product. A 1-level parts delivery file that stores a 1-level parts delivery record that classifies and aggregates parts according to the bucket corresponding to the delivery date of the product order record, and a 1-level parts inventory record that indicates the inventory quantity of the 1-level parts And a product master including a product number and name of each product and a process procedure number representing each process of the production process of the product. Further, the process procedure information includes a process procedure master that determines all processes related to product manufacturing, a process master that determines lead time and production capacity of each process of the process procedure master, each process of the process procedure master, and the process. The rough process master including the lead time of the total process calculated from the process lead time and the production capacity of the process master corresponding to, and the rough process master including the minimum, standard, and maximum production capacities of the total process.

[0007]

Next, the present invention will be described with reference to the drawings.

Referring to FIG. 1 showing the configuration of an embodiment of the present invention, in this embodiment, a sales planning system 1 for outputting order orders, a standard production schedule 2 which is a scheduled production schedule of products, and manufacturing of products. Based on the manufacturing order file 24 that manages the product and the material requirement plan 3 that generates the one-level parts delivery file 25 that associates the parts that make up the product with the product order, the stock status of the parts necessary for the production of the product is determined. Inventory information 4 having a 1-level parts inventory file 23 shown, a manufacturing order file 24, a 1-level parts delivery file 25, a 1-level parts inventory file 23, and an item information file 20 including a product master 22 showing a process procedure of a product, and a process Process procedure information file 3 with procedure information
And a standard production planning apparatus 10 for drafting a production execution plan 5 of the product based on 0.

The standard production planning apparatus 10 further includes an item information file 20 including a product master 22, a 1-level parts inventory file 23, a manufacturing order file 24, and a 1-level parts delivery file 25, and a process procedure showing the manufacturing process of the product. Referring to the information file 30, a part check unit 16 for checking product constituent parts and a process procedure master 31
Rough process master 33 determined by and the process master 32
The load check unit 17 that adjusts the production capacity by referring to
A rough cut scheduling unit having the following, and a rough process master 33 of a process procedure information file 30 that defines a production process of a product, a process procedure master 31 and a process master 32.
The rough process design unit 13 created by

Further, referring to FIG. 8 exemplifying the order record 80 which is an output of the sales planning system 1, an order number 81 for managing orders, a product number 82 of the order, a delivery date 83 of the order, and a quantity 84 of the order. User number 85 indicating the orderer
And an urgency level 86 indicating the manufacturing urgency level of the order. The information processed by the rough cut scheduling unit 14 includes the manufacturing master record 220 of the manufacturing master 22 illustrated in FIG. 6A and the 1-level parts inventory record 230 of the 1-level parts inventory file 23 illustrated in FIG. 6B.
The manufacturing order record 240 of the manufacturing order file 24 illustrated in FIG. 6C and the 1-level parts shipping record 250 of the 1-level parts shipping file 25 illustrated in FIG. 6D will be described. Product master record 2
The reference numeral 20 includes a product number 221 indicating an ordered product, a product name 222 of the product, and a process procedure number 223 indicating a pattern of a series of processes for manufacturing the product. The 1-level parts inventory record 230 indicates the stock status of each of the parts constituting the product managed by the inventory information 4, and the parts indicating the 1-level part number 231 for identifying the part and the name of the part. The name 232 and the on-hand inventory quantity 233 indicating the inventory quantity of the part are included. Manufacturing order record 240
Is the order number 241 given in the material requirement plan, the product number 221 of the product manufactured by the order, the start date 243 of manufacturing, the delivery date 244 of the product, and the product quantity 245.
And The 1-level parts delivery record 250 is a record indicating the delivery quantity of the parts in the material requirement plan 3 based on the inventory information 4, and is the production order 241, the 1-level part number 252 indicating the parts, and the delivery date of the delivery date. 253 and a delivery quantity 254 indicating the quantity of the parts.

Furthermore, the process procedure master record 3 of the process procedure master 31 illustrated in FIG. 7A is used for the information created by the rough process designing unit 13 of the standard production planning apparatus 10.
10, a process master record 320 of the process master 32 illustrated in FIG. 7B, and a rough process master record 330 of the rough process master 33 illustrated in FIG. 7C will be described. The process procedure master record 310 includes a process procedure number 223 indicating a manufacturing process corresponding to a product and a series of rough process numbers 3121 to 312 determined by disassembling the manufacturing process.
Including n. The process master record 320 includes a process number 321 indicating each process, a process name 322 of the process, a lead time 323 of the process, and a production capacity 324 indicating the production capacity of the process. Rough process master record 3
30 is each rough process 3 of the process procedure master record 310.
Based on the process number 321 of the process master record 320 corresponding to each of 121 to 312n, the rough process number 331 indicating all the production processes of the product, the rough process name 332 of the rough process, and the process lead time of each process. 323
A rough process lead time 333 calculated from the above, a series of processes 3341 to 334n constituting the rough process, a minimum capacity value / bucket 335 indicating the minimum production capacity per bucket of a product corresponding to the rough process, The standard capacity value / bucket 336 indicating the standard production capacity of the product and the maximum capacity value / bucket 337 indicating the maximum production capacity of the product are included.

Next, the rough cut scheduling unit 14
The operation of the component check unit 16 and the load check unit 17 of FIG. 4 will be described with reference to FIGS. 4 and 5, respectively. The operation of the component check unit 16 extracts a one-level component delivery record 250 having the same manufacturing order ( Step 16
1). The parts are totaled for each part and each delivery bucket, and the total number of deliveries is calculated (step 162). The on-hand inventory amount 233 of the one-level component inventory record 230 of the component is compared (step 163). When the delivery quantity is larger than the on-hand inventory quantity, the delivery record 250 exceeding the on-hand inventory quantity is moved to the next bucket (step 164).

The operation of the load check unit 17 calculates a total lead time value for each rough process and each bucket (step 171). The total lead time value is calculated by using the product number 22 which is the same as the product number 221 of the manufacturing order record 240.
The product master record 220 having 1 is searched to obtain the process procedure number 223 of the product. The process procedure number 223
To a series of rough process 3 of process procedure master record 210
121 to 312n are obtained. The rough steps 3121 to 3
Based on the process lead time 332 and the production capacity 324 of the process master record 320 corresponding to 12n, the total lead time 333 is calculated for each rough process and each baguette. Comparing the total lead time 333 with the maximum ability value 336, when the total lead time 333 exceeds the maximum ability,
A warning is issued to the relevant manufacturing order (step 17).
2) Equalize the total read time (step 17)
3).

The rough cut scheduling unit 14 described above
On the other hand, the operation of the rough process design unit 13 that provides the rough process master file 33 will be described with reference to FIG. 3. The input / output device 133 decomposes the product production process into rough processes, and the process procedure master record Each rough process is set to 310 (step 131). Process procedure master record 31
For each process 321 of the process master 320 corresponding to each rough process 3121 to 312n of 0, the initial value of the process lead time 323 and the production capacity 324 are set to the input / output device 13
Confirmation or update is performed from step 3 (step 132). The confirmed or updated process master records 320 are collected for all the corresponding rough processes 3121 to 312n, and the minimum capability value / bucket 335, standard capability value / bucket 336, maximum capability value / bucket 337 are calculated, and the rough process is performed. A master record 330 is created. As described above, in this embodiment, the simple standard production planning apparatus 10 that reflects the component parts of the product, the production process, the lead time, and the production capacity is realized.

[0015]

As described above, according to the present invention, it is possible to make a high-speed and reliable production execution plan by simplifying important process information and parts information for the production execution plan. it can.

[Brief description of drawings]

FIG. 1 is a diagram showing a configuration of an embodiment of the present invention.

FIG. 2 is a diagram showing a configuration of a rough cut scheduling unit in FIG.

FIG. 3 is a diagram showing a configuration of a rough process design unit in FIG.

FIG. 4 is a diagram showing a flow of operations of the component check unit of FIG.

FIG. 5 is a diagram showing a flow of operations of the load TEC section of FIG. 2;

6A, 6B, 6C, and 6D are a product master record, a 1-level parts inventory record, a manufacturing order record, and a 1-level parts delivery record, respectively. It is a figure which illustrates.

7A to 7C are diagrams illustrating a process procedure master record, a process master record, and a rough process master record, respectively.

FIG. 8 is a diagram exemplifying an order record.

[Explanation of symbols]

 1 Sales Planning System 2 Standard Production Schedule Plan 3 Material Requirements Plan 4 Inventory Information 5 Production Implementation Plan 10 Standard Production Planning Device 13 Rough Process Design Department 14 Rough Cut Scheduling Department 20 Item Information File 30 Process Procedure Information File

Claims (3)

[Claims] [Claim 1] A standard production planning apparatus for formulating a simple production execution plan for a ordered product, based on an ordered order, a standard production schedule plan, and a material requirement plan acquired from a sales planning system, Based on the item information including the information on the inventory and delivery of the required parts of the product, the rough cut scheduling unit that formulates the standard production plan that adjusts the production capacity of the production process, and all the processes related to the production of each product A standard production planning apparatus, comprising: a rough process design section for creating process procedure information including a rough process master indicating a total lead time and a total production capacity. 2. The item information includes a manufacturing order file storing a manufacturing order record obtained by classifying and collecting order orders for each ordered product and each bucket corresponding to a delivery date, and one rank lower rank of each product. A 1-level parts delivery file that stores a 1-level parts delivery record that classifies and aggregates 1-level parts that represent parts according to the bucket corresponding to the delivery date of the product order record, and the inventory quantity of the 1-level parts A 1-level parts inventory file storing a 1-level parts inventory record, and a product master consisting of a product number and a name of each product, and a process procedure number representing each process of the production process of the product. The standard production planning device according to item 1. 3. The process procedure information includes a process procedure master that defines all processes related to manufacturing of a product, a process master that determines lead time and production capacity of each process of the process procedure master, and each of the process procedure masters. And a rough process master including the lead time of the total process calculated based on the process lead time and the production capacity of the process master corresponding to the process and the minimum, standard, and maximum production capacities of the total process. The standard production planning apparatus according to claim 1, characterized in that.