JPH09128440A - Production planning method and system using it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To support the intention dicision of a person in charge of production schedule at the time of adjusting a schedule by analyzing a production schedule including a problem so as to narrow down the contents of adjustment for extracting the point of the problem and improving the schedule. SOLUTION: This system consists of an MPU controller 2, a read time calculation device 1, an MRP developing device 8, a countermeasure planing device 101, a data input/output device 12, a data storage device 11, etc. The system supports the intension decision at the time of deciding various kinds of countermeasures to the production schedule by presenting the adjusting plan for the production schedule by a production schedule preparing function, an inventory management function, an operation load situation analyzing function, an assignment situation analyzing function, and a countermeasure plan presenting function, etc. When an execution disabled situation is generated in the production schedle based on a given production schedule, the system analyzes the situation to narrow the contents of the schedule adjustment for grasping a problem generating situation and solving the problem to present the schedule adjusting plan to support the person in charge of the planning to prepare an executable production schedule.

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 for a manufacturing system, and if the produced production plan has a problem and cannot be executed, a measure for solving the problem. The present invention relates to a production planning system that can support planning adjustment work by presenting.

[0002]

2. Description of the Related Art As a conventional technique relating to a production plan, there is known a technique described in Japanese Patent Application Laid-Open No. 2-311250 that supports adjustment of a production plan in which a problem has occurred.

If the production plan planning method according to the present invention or a production plan prepared using another method is problematic and infeasible, the production quantity is changed or completed with respect to the production plan. It is necessary to make adjustments such as shifting the completion date of the item lot to make the plan feasible. However, if the planner takes measures based only on the results of the production planning, it will be feasible to make adjustments for which finished item lot, and the planner will be satisfied. It is difficult to know immediately what to do. Therefore, at present, the adjustment contents are decided by performing many trials and errors. In such a situation, if it is possible to provide a mechanism that can teach effective adjustment content according to the plan adjustment policy considered by the planner, it is possible to significantly reduce the plan adjustment time. Instead, it becomes possible to make a more appropriate plan.

[0004]

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention
According to the technology described in Japanese Patent Publication No. 0, it is possible to confirm the situation in which the schedule plan of each process changes with respect to the plan change content decided by the planner for a production plan having a problem, but Since no support is provided for investigating the cause and deciding the adjustment contents for improving the plan, the planner himself has to perform the work of considering the produced production plan and deciding the adjustment contents. Therefore, new problems may occur depending on the changes decided by the planner, and it takes a lot of time to finally create a viable production plan.

Therefore, in the present invention, by analyzing the work load situation of the production plan including the problem with respect to the production capacity in each process and the allocation situation of the stock amount of each item to the production plan, the problem point is extracted and the plan is planned. The purpose is to support the decision making of planners in the case of plan adjustments by narrowing down the details of adjustments for improvement.

[0006]

In order to achieve the above object, the present invention relates to a completion schedule indicating the completion date, quantity, etc. of a completed item requested by a user, and In a production planning system, which handles a manufacturing process as at least one shop and determines a production period until the finished item is completed by calculating a manufacturable period of the item in the shop, the work capacity provided in the shop And a means for managing the surplus capacity of the shop derived from the work capacity and the work load given to the shop, and when a production schedule that satisfies the completion date specified in the completion schedule cannot be created. , A means for determining a deadline for securing the work amount necessary for the item from the surplus capacity of the shop, and Those comprising means for calculating a producible date of the completion item on the basis of the date determined for each shop.

More specifically, with respect to the completion schedule indicating the completion date, quantity, etc. of the completed item requested by the user, the manufacturing process of the items constituting the completed item is handled as at least one shop, and In a production planning system that calculates the period during which the item can be manufactured in the shop and determines the production schedule until the completed item is completed, the manufactured item is manufactured so that there is no delay in the completion date of each completed item due to the completed schedule. Production plan creation means for setting the work start date of each item based on the completion date of the item, inventory quantity management means for managing the current storage amount and future planned storage amount of each item handled, and the production plan creation means For each production item, the relationship between the daily requirement amount, the inventory amount and the planned storage amount for each item, and the daily work amount and There is a problem with the production plan situation analysis means that analyzes the relationship with the above and calculates the shortage / amount and surplus time / amount of the item, and the overload time / amount and margin time / amount of the shop, and the production plan. In this case, for the selected finished product lot, the measure planning means for formulating the production available date and the result obtained by the measure planning means are displayed based on the feature amount obtained by the production plan status analysis means. According to the present invention, the user has a measure proposal presenting means capable of making a decision as to whether or not to implement the measure.

Conventionally, a planner spends a lot of time on trial and error of various adjustments in order to decide a satisfactory adjustment content from a large amount of adjustment content for a huge amount of data. However, according to the production planning system of the present invention, with respect to a plan including a problem, an adjustment is made to create a plan that can be executed in a short time by analyzing a plan condition of an item to be planned or a shop. Since the plan can be presented, the planner can reduce the time spent for producing the production plan, and can obtain the production plan according to the evaluation measure of the planner. In other words, by analyzing the surplus capacity of each shop, it is possible to present an adjustment plan when the completion schedule changes.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of the production planning system according to the present invention will be described below.

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

In the figure, 1000 is a production planning system, 11
00 is an order processing system, 1200 is a manufacturing system, 1
300 is a make-to-stock production planning system.

[0012] Using the make-to-stock production planning system 1300, the planner, based on the make-to-stock quantity predicted for future orders,
Create a product completion schedule. The product completion schedule is created as a set of production request information with a note number for each set of product name, number of products, and completion date. Completion schedule of the created products, production planning system 1
Passed to 000.

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

The order processing system 1100 processes an order from a customer and passes order information that specifies the number of orders and a requested delivery date to the production planning system 1000. Further, the production planning system 1000 obtains an answer of the contract delivery date based on the production schedule.

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

The production planning system 1000 has a product completion schedule created by the make-to-stock production planning system 1300, order information and production schedules passed from the order processing system 1100, and a manufacturing system 1200.
Has a data storage device 11 for storing information and the like, and a data input / output device 12 for providing a user interface with a planner.

Further, it has an MRP control device 2, an MRP expansion 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 40, and a plan deletion device 104. There is.

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

First, each shop is grouped and each shop is called a shop group. Each shop group is a set of shops that are capable of substituting for each other's work and do not have a context in the manufacturing process that they are in charge of. For example, a shop group of shops that perform assembly work and a painting work A shop group of shops, a shop group of shops that perform processing work, and the like can be considered.

Next, the shop groups are arranged by the method of topological sorting. In other words, for each product, when the target shops are arranged in the order in which the manufacturing process progresses, and the corresponding shops are arranged, and the number of the shop group to which each shop belongs is arranged, the smaller number is always better. Number each shop group so that it precedes the higher numbers. As a result, in producing any product, the number of the shop group to which the shop in charge of the earlier manufacturing process belongs is smaller than the number of the shop group to which the shop in charge of the later manufacturing process belongs. Therefore, the smaller-numbered shop group is called an upstream shop group, and the higher-numbered shop group is called a downstream shop group.

The products produced in each shop are referred to as items, and the relationship between each item and the shop that manufactures the item is explained as being set in advance in the data storage device 11 as information about the manufacturing system. To do. Also,
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. The procurement shop is a system for ordering and procuring the net requirement amount, which is obtained by subtracting the inventory amount from the requirement amount, for the item concerned.

The manufacturing system 1200 also manages the inventory quantity of each item, and sends the current inventory information to the data storage device 11 of the production planning system 1000. Then, the item / quantity manufactured in each shop and the item / quantity procured in the procurement shop are added to the inventory information.

The operation of the production planning system 1000 according to this embodiment will be described below.

The production planning system 100 according to this embodiment
0 first creates a production plan based on the product completion schedule created by the expected production planning system 1300.

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

First, the data storage device 1 stores the product completion schedule received from the expected production planning system 1300.
When the MRP execution instruction 18 is received from the data input / output device 12 after it is stored in 1, the MRP control device 2 sends the MRP expansion instruction 30 to the MRP expansion device 8 and the production request information corresponding to each order number in the completion schedule. The name of the product (completed item), the total required amount of the completed 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 for each shop belonging to the most downstream shop group (202), the total required for each item manufactured in the shop in sequence. The inventory quantity stored in the data storage device 11 is subtracted from the quantity to determine 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, the net required amount of each item obtained for each shop and the completion date of each item are passed to the work amount calculation device 3. At this time, the required amount for each order number is also obtained.

The work amount calculating device 3 calculates the completed work amount 26 for each shop (208), and the lead time calculating device 1
Pass to. Here, the completion work amount is the amount of work of the shop required for manufacturing all the items having the completion date as the completion date for each day.

On the other hand, in the lead time calculation apparatus 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 each shop (207, 208, 209). The method of calculating the lead time will be described in detail later.

Next, in the MRP expanding device 8, each item is sequentially made an expanding target item, and the lead time 14 of the expanding target item obtained by the lead time calculating device 1 is subtracted from the completion date to manufacture the expanding target item. The start date is determined, the items (sub-items) necessary for manufacturing the development target item are obtained, and the day before the start of manufacturing of the determined development target item is set as the completion date of the sub-item. In addition, the required amount expansion process for the total required amount is performed for each obtained child item, and the number of each child item required to manufacture the item to be developed is obtained (210 to 21).
3).

As described above, the production plan for the most downstream shop group is completed. Next, the MRP control device 2 sequentially traces upstream, and repeats the processing after the reference numeral 203 in FIG. 2 for each shop group ( 214, 2
15). However, for the procurement shop, simply set the lead time (procurement lead time) to the period required to procure the item, and set the start date obtained from the procurement lead time to
It is the date when the item is ordered.

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 calculation device 1 will be described. As described above, the lead time calculation device 1 predicts the lead time in each process in consideration of the load of each shop.

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

Further, in a job shop in which each shop is in charge of the work of a job, the average lead time increases almost in proportion to the in-shop work in process, while the production speed It is well known from past studies using queuing theory that it saturates and stops increasing at a certain level even if it increases. This fact indicates that there is an optimal work-in-progress level and production speed, and even if a job is input, the lead time per item only increases and the production speed hardly increases. .

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

Therefore, in this embodiment, the lead time is predicted by the method shown in FIG. 3 as follows. However, it is assumed that the cycle time (input interval = calculation interval for one item) and the lead time for each item at the optimum production speed in each shop are known for each shop.

As described above, first, the work amount calculation device 3 determines the completed work amount of each day of the target shop. The completion work amount is the total work amount of the items whose completion date is the relevant day, and as shown in FIG. 3, the product of the number of items and the standard time ST required to manufacture one of the items is It will be the sum of all items with that date as the completion date. At this time, for each order number that uses items whose completion date is
Also find the amount of work at the target shop.

Next, the work amount distribution and the input time are calculated. Here, the work amount distribution is determined by sequentially advancing the completed work amount 26 in each shop obtained by the work amount calculation device 3 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, the completion time (= the production time of the last one in the item group) is set to coincide with the end of the completion date. Next, the width from the first production time to the last production time,
The normalization completion work amount on that day is calculated as the standard cycle time, and the production time of the first one is determined. Further, the time obtained by subtracting the lead time for each item becomes the time of introduction of the first item, that is, the start time of the item group A.
However, like the item group B, when the first production time of the item group that will be completed on the next day is before the completion date of its own, the completion time of the item group B will match this. Set to allow.

Here, the normalized completed work amount is the standard work amount (S of the items manufactured in the shop).
It is normalized by dividing the weighted average value of T by the manufacturing quantity ratio). Further, the standard cycle time is a weighted average value of cycle times of items manufactured in the shop according to the manufacturing quantity ratio. 1
The standard lead time per piece is the weighted average value of the lead time per piece of the item manufactured in the shop, which is based on the manufacturing quantity ratio.

Next, the interval between the start time and the completion time is set as the lead time. If the work of the item completed after the completion date is delayed before the completion date, the lead time is increased accordingly.

By the way, in the present embodiment, when the production plan is adjusted as will be described later, the capacity of the shop may be set to a different value for each day. Therefore, the operation in this case will be described.

For example, since the standard cycle time and the standard lead time become 1 / α when the capacity becomes α times, the width and inclination in FIG. 3 may be multiplied by 1 / α. However, in this case, the calculation becomes complicated at the turning point of the ability, as shown on the left side of FIG. Therefore, in this embodiment, the configuration shown on the right side of FIG. 4 is adopted. That is, the fact that the ability is increased by α means that the time axis is extended by α times, and the lead time is calculated by setting the width and the inclination on this expanded / contracted time axis as in FIG. 3.

As described above, the lead time calculation apparatus 1 sets the lead time of each process in consideration of the total work amount of the shop for each shop.

As described above, in order to predict the lead time, the parameters for prediction are necessary. Here, the prediction parameters are ST, cycle time, and
It is the lead time per piece. These are used as information about the manufacturing system 1200 and are included in the data storage device 1.
1 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. Neural networks are
Since each of the lead time calculation device 1 and the work amount calculation device 3 has the pattern conversion ability between the input data and the output data and the pattern learning ability, for example, the following data is used for each neural network. It is possible to calculate the lead time for a new input by pattern conversion by learning.

Input: Ability of each shop, completed work output: Lead time In addition, regarding the theory of neural networks, Rumelhardt DEE, McLarend JL and the PDP Research Group, 1
986, Parallel Distributed Processing: MI Press (Remelhart DE,
Maclelland JL and The PDP Research group, 198
6, 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 coupling 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, a production / procurement plan for each order number is created by the production planning system 1000 for each shop according to the product completion schedule created by the expected production planning system 1300, and the data storage device is used. 11
Is stored. At this point, the production / procurement plan is
It is assumed that the product can be created so that the completion schedule of the product can be satisfied, that is, the start date or order date of the item is not set before the present time.

After that, the future production quantity is predicted by the forecast production planning system 1300, and the customer's order is received earlier than the time when the production quantity exceeds the production quantity on the completion schedule of the created product or the completion of the item is scheduled. When a request is made, the order processing system 1100 sends order information that specifies a product name, a required quantity, and a requested delivery date for which additional production is required, to the data storage device 11 of the production planning system 1000. Then, the production planning system creates the production request information that indicates the product name, the production amount, and the completion date that satisfy the order contents indicated by the above order information, and adds a new order number to the product completion schedule. In addition, the MRP expansion device 8 is instructed to regenerate the production plan.

MRP expansion device 8, work amount calculation device 3, lead time calculation device 1 instructed to regenerate the production plan
Reads the current stock amount from the data storage device 11,
As described above, the production / procurement plan for each order number is created for each shop and stored in the data storage device 11. At this time,
From the viewpoint of the amount of work, the work amount analysis device 27 and the production plan determination device 101 determine whether or not an executable production plan that satisfies the completion schedule of this new product is drawn up. It is determined whether or not a workable production plan that satisfies the production demands of all the order numbers allocated to the demands from customers can be drafted. In addition, the MRP expansion device 8 and the production plan determination device 101 make a plan from the viewpoint of the inventory quantity of the items to be procured from the outside, whether or not a feasible production plan satisfying the completion schedule of this new product is made. If not, it is determined whether or not a viable production plan that satisfies all the production demands of the order numbers allocated to the demand from the customer can be drafted.

If a feasible production plan satisfying the completion schedule of a new product is made in terms of both the work amount and the inventory amount, further work for adjusting the production plan is unnecessary, but is not necessary. If it is not possible to formulate a possible production plan, it is necessary to take measures. Therefore, in the following, when a viable production plan could not be drawn up, when new products could be produced, and in order to satisfy the completion schedule of new products, the requirements from customers were allocated. This paper describes a countermeasure planning support function that presents to the user when to set the production time of each order in case of delaying the completion schedule of some orders that have not been done.

The processing is performed according to the procedure shown below.
First, based on the output result of the lead time calculation device 1,
The work load analyzer 27 analyzes the work load situation of each production process. Here, from the work load situation for each production process, the period when the work load is excessive with respect to the production capacity, the period when the work load does not reach the production capacity and there is a capacity margin, and the amount thereof are clarified. To

Next, when developing the required amount, the MRP developing device 8 analyzes the allocation status of the current stock / planned stock quantity for the daily required quantity of each item. Here, from the allocation status of each item, the period when the required amount is excessive with respect to the available amount, the period when the required amount is less than the available amount, and the excess inventory exists and its amount are clarified. To do.

As described above, after clarifying the production capacity and the surplus amount / period relating to the item, the information concerning the constituent item of the order number for which the production time is now set and the production process thereof are retrieved from the data storage device 11, Countermeasure planning device 10
In 0, the time when production is possible is set for the order number. The information regarding the set order number is presented to the user by the data input / output device 12, and after the user makes a decision, the MRP execution instruction according to the decision content is sent to the MRP control device 2.

First, a method of analyzing the work load status with respect to the production capacity of each process performed by the work amount analyzing apparatus 27 will be described.

It is assumed that the work load amount with respect to the daily production capacity is as shown in FIG. 5 in the process in which one item constituting the order number for which the work completion date is changed is manufactured. At this time, in the lead time calculation device 1, the overload on the daily production capacity is progressively advanced from the last day of the production planning period to the present by the method described with reference to FIG. As a result, if there is an overload on the current day, the amount of advance of the overload is checked for each day sequentially from the present day to the future. At that time, the work load is more excessive than the production capacity within the period until the earliest amount of advance overload in the future reaches 0 (currently +2 days in this example). However, there is a possibility that there is a margin in capacity after the overload occurrence boundary date in the figure. Therefore, from the boundary date of overload occurrence, the surplus capacity is moved backward and assigned to future overload. Therefore, if the amount of surplus capacity on the last day of the planning period is positive, it is known that there is surplus capacity, and it is possible to check whether there is surplus capacity within the planning period. is there. In the graph showing the amount of surplus capacity pushed backward in FIG. 5, the surplus capacity currently existing in the period of +3 days to +5 days is allocated to the overload of n−3 days and n−2 days, so that it is currently +3 days. There is a surplus capacity of a in the period of up to n-2 days, and a surplus capacity of b in the period of n-1 days to n days. In other words, the surplus capacity a is the postponement amount of the surplus capacity that can be ensured after the overload occurrence boundary date, and similarly, the b is the postponement amount that can be ensured after (n-1) days. Therefore, if the work load x in the target process of the order number for changing the work completion date is, for example, a <x ≦ b, then n
-1 day is the earliest production possible date. Also,
The order number, which is a work load larger than the surplus capacity by period in the figure, cannot be accepted within the production plan target period and needs to be incorporated in the next production plan. As described above, the information about the production process obtained by the work amount analyzing device 27 is stored in the data storage device 11.

Next, a method of analyzing the allocation status of the current stock / planned stock quantity with respect to the daily required quantity for each item, which is performed in the MRP expanding device 8, will be described.

The inventory transition within the procurement lead time period calculated from the daily required quantity and the current stock / planned stock quantity for one item constituting the order number for which the work completion date is changed,
It is assumed that it is as shown in FIG. If there is a negative day in the inventory change as in this example, a shortage will occur, and if the usage amount corresponding to the shortage is not reduced, the production plan cannot be executed. Can not. Therefore, as a result of taking measures to reduce the usage amount, such as by canceling the production of the order number within that period and delaying the work completion date,
A surplus may occur in the future. This can be known from the inventory quantity transition when the shortage indicated by the colored circles in FIG. 6 is resolved. In this example, if there are 40 unused item quantities in the procurement lead time period of the current item after +5 days and the quantity of the relevant item used for the order number for changing the completion date is 40 or less, It can be seen that it can be procured at +5 days now. If more parts are needed, it can be seen that by arranging parts from now on, it can be procured now +7 days after the procurement lead time. As described above, the information on the allocation status of the item obtained by the MRP developing device 8 is stored in the data storage device 11.

Next, a method of setting the producible period for the order number performed by the countermeasure planning apparatus 100 will be described with reference to FIGS. 7 and 21. However, the product produced as the order number is composed of item 1 and item 2, and item 1 is composed of item 3 and item 4. Also,
Among them, the item 4 is a procured item.

First, the period in which the completion date cannot be set is specified first. Here, the completion date unsettable period means that even if the completion date is set on the completion schedule for the target order number for which the completion schedule is changed, the overload amount will increase in any production process, or This is the period when the shortage of procured items increases.

In order to obtain this period, data storage 1
Information regarding the production process and the procurement item regarding the component item of the order number is extracted from 1, and the manufacture possible date is calculated for each production process and the procurement possible date is calculated for each procurement item (step 701).

Next, the earliest completion date is obtained for the lowest item group (step 702). Here, the earliest completion date is defined as the earliest possible date for manufacturing / procuring all the item groups obtained from the possible manufacturing / procuring dates of each item having the same parent item. That is, when the lowest item group is only one item, the manufacture / procurement date of the item is the earliest completion date, and when the lowest item group is composed of a plurality of items as in this example. , The latest manufacture / procurement date of those items is the earliest completion date.

Next, paying attention to the next higher item group (step 703), the manufacturing (procurement) possible date of each item (a _u [ _u ; process level (0, 1, 2, ...)], FIG. [A]) and the day after the earliest completion date of the subordinate item group (x _b [ _b ; Process level (1,2,3,
]), And [B] in FIG. 21 is compared with the context (steps 704 to 707). Then, if a _u ≤ x _b (the next day of the earliest completion date of the subordinate item group is in the future or on the same day), then x _b is the earliest completion date of the item group, and x x is newly _added to x. Set the day after _b (step 70)
9). If x _b < _au (the earliest completion date of the item group is in the future), a _u is the earliest completion date of the item group, and x _b is set to the day after a _u (step 708). By repeating this process up to the top item (step 7
11), the provisional production time of the order number is set (step 712). At this time, if there is an item which does not have a manufacture / procureable date in the planning period among the constituent items, it is determined that the production in the planning period is impossible, and the data input / output device 12 is notified of that fact. Present.

In this way, when the provisional production time can be set, the completion date of the order number on the completion schedule is changed to that day (step 713), and the MRP controller 1
8 to send an MRP execution instruction (step 714). As a result, the MRP control device 18 causes the lead time planning device 1 to
And the MRP expansion device 8 are instructed to start processing, respectively, but when the work load status changes to the production process, the overload amount increases compared to before the completion schedule change, and when the item allocation status change to the procurement item changes, the shortage amount becomes the completion schedule. It is checked whether the number has increased compared to the value before the change (step 715). At this time, if an increase is recognized in any of the production processes or procurement items (step 716), the MRP control device 2 then instructs the lead time planning device 1 and the MRP expansion device 8 to stop the processing. Issue, change the completion date of the order number on the completion schedule to the next day, and issue a processing start instruction again (step 71).
4). This process is applied to all production processes / procured items.
By repeating the process until the day when the overload / deficiency does not increase is found, the production-enabled period of the order number is set (step 717). Here, the set producible period is stored in the data storage device 11.

By the way, the data input / output device 12 is responsible for generating the production plan as described above, confirming whether or not there is a problem in the generated production plan, and adjusting the production plan when there is a problem. This is done via the physical user interface provided.

Hereinafter, the operation of the production planning system for confirming whether or not there is a problem in the generated production plan and the operation of adjusting the production plan when there is a problem will be described in correspondence with the operation of such a user interface. To do.

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

FIG. 8 is a screen initially displayed by the data input / output device 12 when the production planning system is activated.

When the "initial plan" command in the command menu is picked with the mouse, the data input / output device 12
Instructs the MRP control device 2 to execute MRP.

By this instruction, the production plan is generated as described above. The order processing system 1100
Thus, the production plan reflecting the new received order information is also generated by picking the "initial plan" command with the mouse.

On the other hand, after the production plan is generated, when the "problem analysis" command 41 in the command menu in FIG. 8 is picked with the mouse, the problem analysis instruction 19 of FIG. 1 is sent. The problem analysis device 7 uses this problem analysis instruction 19
In response, the generated production plan is input from the data storage device 11.

The problem analysis device 7 searches the contents of the production plan, and if the start date of the shop on the most upstream side is before the current date (that is, if the production is not started before the current date, the completion of the product is completed). A list of items for which the schedule cannot be 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 parts procured from the outside,
The order date is before the current date (that is, if the order is not placed before the current date, the production plan cannot be satisfied).
It is also possible to create a list of items to be obtained and output the result to the data input / output device 12 for display.

FIG. 9 shows an output screen of the problem analysis result.

In the problem section display table 42 in FIG. 9, the horizontal axis represents the period of a half month unit, and the vertical axis represents the product category.

Each matrix delimited by the vertical and horizontal axes has a delivery date within the range represented by the horizontal axis, and the manufacturing start date or the order date of the externally procured parts is set in the corresponding item before the present date. If there are some that are not satisfied with the completion schedule of the product, they are displayed in dark color. At that time, the number of cases, quantity, number of delays (number of products whose start date of the upstream shop is earlier than the current date), maximum delay (most The number of days from the start date of the shop on the upstream side to the current date) is 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 matrix A matrix for which detailed information is to be referred is picked up with the mouse. FIG. 9 shows “Period: March / Upper, Category:
It indicates that the matrix portion of "2" is picked.

Insufficient stock / Launch start date Display of order list Pick the "order list" menu 44 from the command menu. By picking the "order list" menu, the late-start order list 43 is displayed as detailed information. There is a shortage of stock in the delayed start list 43 (the order date of the externally procured parts used is before the current date)
Or, the order number that is behind the start (the date when the manufacturing start date is before the current date), inventory shortage for the product of that order number, the number of items that are behind the start (number of related cases), delivery date and , Delay / margin is 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. 9, the order number / date problem occurrence point display table 46 shown in FIG. 10 is displayed.

In the note number / date problem occurrence point display table 46 in FIG. 10, the horizontal axis indicates the date and the vertical axis indicates the note number.

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

In the problem location display table 46 by order number / date,
The dark matrix shows the problem occurrence point.The maximum delay and the number of items for which the order number is delayed or insufficient for the product of the order number are displayed as information for indicating the problem occurrence status. There is.

Here, further, in the problem number display table 46 by order number / date, the detailed information of the matrix in which the problem occurs 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 with the mouse. In Fig. 10, "Period: 3/4, note number: 1
This indicates that the "003" 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. The detailed information list 47 displays the product name, model, quantity, start delay days (number of days from the start date of manufacture to the current date) of the specified order number, and the like.

By picking the "item list" menu 49 instead of the "details" menu 48 for displaying the item list of delayed start, the start delay list screen 50 shown in FIG. 11 is displayed for the products of the specified order number. 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 on the data input / output device 12 by the problem analysis device 7 described above, the planner must adjust the production plan. .

The adjustment of the production plan can be performed on the display shown in FIG.

FIG. 12 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, and the production amount. It comprises an adjustment menu 151, a plan deletion menu 156, an adjustment execution menu 157, a countermeasure proposal menu 93, a production capacity change start point setting dial 59, a production capacity change end point setting dial 60, a production capacity setting dial 61 and the like.

The display of FIG. 12 is called by the following procedure, and the called problem route display portion 53 is being displayed.
Displays the problem route. The route refers to 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 / starting delay has occurred) is selected. For example, inventory shortage / delayed item list 5 in FIG.
In 0, after picking the "partition plate" with the mouse,
By picking the "End" button 52 with the mouse,
"Partition board" is selected as the target item.

Production plan adjustment instruction Pick the "adjustment" menu 51 in the command menu of the output screen of FIG.

Problem Analysis As a result, the problem analysis instruction 19 is sent from the data input / output device 12. Upon receiving the problem analysis instruction 19, the problem analysis device 7 receives the production plan 2 from the data storage device 11.
Enter 1.

Further, the problem analysis device 7 obtains each shop used to manufacture the countermeasure item selected in and its load status, and outputs the result 20 to the data input / output device 1.
Output to 2.

Problem Route Display The data input / output device 12 displays the problem analysis result 20 on the problem route display unit 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 volume) 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. The problem route is indicated by the bold frame in the figure, and the shops 8, 7 and
3, 2, 1 indicates that the item is manufactured. In addition, one thick frame rectangle indicates the schedule in one shop, and the horizontal axis direction indicates the lead time of the process.

By constructing the problem route display 53 in this way, the production planner can easily understand the problem route, and at the same time, in terms of the amount of work, he / she will take a countermeasure from a place with a large degree of complexity. It will be possible to make a decision easily.

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

At this time, instead of stopping the production or reducing the production amount for the displayed order number,
When it is possible to immediately make a decision to solve the problem by shifting the production time to the future, by picking the “completion of change plan of completion date” in the area 95, the measure planning instruction for the order number will be taken. MR sent to device 100
An instruction to that effect is sent to the P control device 18. The completion time of the order number obtained as a result is stored in the data storage device 11 and displayed as shown in FIG.

Further, as a final judgment, if it is stored that the 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 in terms of the amount of work and the amount of inventory performed by the MRP expansion device 8, the work amount analysis device 27, and the production plan execution determination device 101 described above is performed when the production plan is generated. Alternatively, when the countermeasure proposal menu 93 is picked up, it may be performed based on the detailed production plan stored in the data storage device 11.

As a result, the production planner was able to obtain the guideline for the countermeasure for the countermeasure item, so the countermeasure is determined based on this guideline and the production plan is adjusted.

Now, in the adjustment of the production plan, 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, the plan deletion menu 156. Using.

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 change shop In the problem route in the problem route display portion 53, after picking the shop whose production capacity is to be changed with the mouse, the capability adjustment menu 57 is selected. For example, s in FIG.
Pick the part surrounded by the thick line of hop3 with the mouse.

Display on 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 setting dial 59 and production capacity change end point setting dial 60 are picked up with a mouse to start production capacity change start point 64 and production capacity change end point 65.
To move left and right. In 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, and when the right button is picked, it is moved to the right.

Production capacity change By picking the production capacity setting dial 61 with the mouse, the production capacity change start point 64 and the production capacity change end point 6
Change the production capacity of the section between 5. 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 reduced), and if the right button is picked, production capacity is increased (production capacity is reduced). Increase).

After that, when the adjustment execution menu 157 is picked up, the data input / output device 12 issues a production capacity adjustment instruction 15 to the production capacity adjustment device 4 based on the production capacity change result. 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 execution device 2
On the basis of the production capacity adjustment result, in cooperation with the MRP expansion device 8, regenerates only the production plan for the order number manufactured by the problem route including the selected shop. 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 corrected production plan is stored in the data storage device 11. However, the production plans for all the order numbers may be regenerated based on the production capacity adjustment result. In addition,
When correcting or generating this production plan, the MRP expansion device 8, the work amount analysis device 27, the production plan execution determination device 1
01 again makes a determination from the aspects of the work amount and the stock amount described above, and updates the determination content of the data storage device 11.

Change the problem route display section. The data input / output device 12 changes the data storage device 11 from the MR.
The P execution result 21 is input, and the production period relating 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, can confirm online how the change in the production capacity affects 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 difference from FIG. 12 is that a lead time display section 90, a capacity increase button 91, and a capacity decrease button 92 are provided. in this case,
Since the above operation is different, this 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 production capacity change start point 64 is picked on that date and with the right mouse button the date is selected. 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 completion date 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. 12 with the mouse.

On the product completion date change screen, 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 date when the customer answers, and the "completion" is the scheduled date of product completion 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, there is a possibility that the delay in starting work can be resolved by bringing this 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 of Completion Date The completion date is changed by picking the completion date change dial 74 with the mouse. For example, in the case of a two-button mouse, if you pick the left mouse button, the completion date will be earlier (move the "Complete" display to the left), and if you pick the right button, the completion date will be later ("Complete""Move the display to the right)
I do.

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, the data input / output device 12 issues a completion date adjustment instruction 16 to the completion date adjustment device 5 based on the completion date change result of. The completion date adjustment device 5 displays the completion date adjustment result and the MRP execution instruction 23 in the MRP.
The control device 2 is instructed. The MRP control device 2 cooperates with the MRP development device 8 based on the completion date adjustment result to regenerate only the production plan of the order number manufactured by the problem route including the selected shop. 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 the production plan is modified or generated, the MRP expansion device 8, the work amount analysis device 27, and the production plan execution 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 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 by a simple operation, and at the same time, can confirm online how the change of the product completion date affects the production plan. .

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. 12 is picked up.

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

That is, when an alternative shop exists in an arbitrary process in the problem route, there is a possibility that the start delay 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 shop for which the production shop is to be changed is picked with the mouse. For example, FIG.
Pick the part of shop3 surrounded by the thick line with the mouse. When there is an alternative shop, the alternative shop display section 81 is displayed.

Also, 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 up, 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 shop. 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 for 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, the production plan execution determination device 101.
Performs the determination again from the aspects of the work amount and the inventory amount described above, and updates the determination content of the data storage device 11.

Change the problem route display section.
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 work start order 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 up when the work start order change menu 150 is picked in FIG.

In the start order change display portion 167 in FIG. 16, when an arbitrary shop in the problem route is selected, the note corresponding to that shop and the shop to be worked within the period including the shop are displayed. 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.

The 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 shop for which the work start order is to be changed is picked with the mouse. For example, in FIG.
Pick the part of shop3 surrounded by the thick line with the mouse. As a result, the sequence shown in the start order change display section 167 is displayed.
On the mat, the order number of the order that generated the selected shop, the work start order of the order number that generated the shop that should work in the period including the shop, the completion date of the order, and the start order. The items for entering the settings are displayed.

Work start order change The start order before and after the order for which the order is changed among the order numbers of the products displayed in the change order display area 167 is input to the change order input item. For example, FIG.
In step 6, in order to change the order number 1005 of the starting order 3 to the starting order 2, the starting order 2 is input to the change order input item.

MRP calculation execution The data input / output device 12 commands the work start order adjustment instruction 31 to the work start order adjustment device 33 based on the result of the work start order change. 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 expansion device so as to satisfy the work start order adjustment result, and regenerates only the production plan for the order number in which the work start order is changed. That is, with the production plans for the other order numbers as a precondition, only the production plans for the countermeasure items are recalculated and the production plans are revised. 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 execution determination device 101 are
Again, judging from the aspects of work volume and inventory volume,
The contents of the judgment of the data storage device 11 are 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 166.
Is corrected and displayed.

As described above, the person in charge of delivery can change the work start order with a simple operation, and at the same time, can confirm online how the change of the work start order affects the production plan. become.

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

FIG. 17 shows a screen for changing the production amount. FIG.
The production volume change screen is shown in the production volume adjustment menu 1 in FIG.
Called by picking 51 with the mouse.

The production amount adjustment display section 177 in FIG.
When you select any shop in the problem route, the order number that generated the shop, its completion date and production volume, margin and delay are displayed.

The production plan adjustment while changing the production amount is as follows.
The procedure is as follows.

Selection of Production Quantity Adjustment Shop In the problem route display portion 53, the shop whose production quantity is to be changed is picked with the mouse. For example, sh in FIG.
Pick the part surrounded by the thick line in op3 with the mouse. As a result, in the format shown in the production amount change display portion 177, the order number that generated the shop, the completion date and the production amount, the margin and the delay are displayed.

Change of production amount 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 on 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. Based on the production amount adjustment result, the MRP control device 2 cooperates with the MRP expansion device so that the MRP control device 2 satisfies the production amount adjustment result, and only the production plan for the order number whose production amount has been changed. Is regenerated. That is, with the production plans for the other order numbers as a precondition, only the production plans for the countermeasure items are recalculated and the production plans are revised. 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 the production plan is corrected or generated, the MRP expansion device 8, the work amount analysis device 27, the production plan execution determination device 1
01 again performs the above-described determination in terms of the work amount and the inventory amount, and updates the content of the determination stored in the data storage device 11.

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 display unit 176 is corrected and displayed.

As described above, the person in charge of production planning can change the production amount by a simple operation, and at the same time, it is possible to 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 number as a countermeasure,
The production plan is adjusted by the following procedure.

FIG. 18 shows the screen for plan deletion. The plan deletion screen in FIG. 18 is called by picking the plan deletion menu 156 in FIG. 12 with the mouse.

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

The production plan adjustment while deleting the 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 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. 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 completion 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. 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 again perform the above-described determination in terms of the work amount and the stock amount, and store the data. The contents of the judgment stored in the device 11 are updated.

Change of 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 in the above manner and finally the production plan without the problem route can be made, the production plan planner makes the production planning system 1000 and the order processing system 1100. If the expected completion date of the order number assigned to the order is before the requested delivery date, instruct to reply the requested delivery date as the contract delivery date,
If the expected completion date of the order number assigned to the order is a day after the requested delivery date, the customer is instructed to reply the date after that as the contract delivery date.

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

As described above, according to the present embodiment, among the production plans, the production allocated to the customer's order is assigned to 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, the planner should be asked how to prioritize the production that has received the order from the customer over the production plan that has not been assigned to the order. Can be suggested.

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

[0179]

According to the present invention, in a production plan based on a given production schedule, when an unexecutable situation occurs, the situation is analyzed to grasp the problem occurrence situation. By narrowing down the contents of the plan adjustment for solving the problem and presenting the plan adjustment plan, the planner can support the production of the executable production plan.

[Brief description of the drawings]

FIG. 1 is a block diagram showing the configuration of a production planning system.

FIG. 2 is a flowchart showing a processing procedure of production plan generation processing.

FIG. 3 is a diagram showing a method of lead time calculation.

FIG. 4 is a diagram showing a method of lead time calculation when the production capacity is changed.

FIG. 5 is a diagram showing a method of analyzing a workload situation in a production plan regarding a production process.

FIG. 6 is a diagram showing an analysis method of an allocation situation in a production plan regarding procured items.

FIG. 7 is a diagram showing a method for planning measures for changing the completion date.

FIG. 8 is a diagram showing one display screen in the graphic user interface.

FIG. 9 is a diagram showing one display screen in the graphic user interface.

FIG. 10 is a diagram showing one display screen in a graphic user interface.

FIG. 11 is a diagram showing one display screen in the graphic user interface.

FIG. 12 is a diagram showing one display screen in the graphic user interface.

FIG. 13 is a diagram showing one display screen in the graphic user interface.

FIG. 14 is a diagram showing one display screen in a graphic user interface.

FIG. 15 is a diagram showing one display screen in the graphic user interface.

FIG. 16 is a diagram showing one display screen in the graphic user interface.

FIG. 17 is a diagram showing one display screen in the graphic user interface.

FIG. 18 is a diagram showing one display screen in the graphic user interface.

FIG. 19 is a diagram showing one display screen in the graphic user interface.

FIG. 20 is a diagram showing one display screen in the graphic user interface.

FIG. 21 is a flowchart showing a method of planning a measure for changing the completion date.

[Explanation of symbols]

1 ... Lead time prediction device 2 ... MRP control device 3 ... Work load calculation device 4 ... Production capacity adjustment device 5 ... Completion date adjustment device 6 ... Alternative shop adjustment device 7 ... Problem analysis device 8 ... MRP development device 9 ... Overload Quantity 10 ... Production plan execution determination result 11 ... Data storage device 12 ... Data input / output device 13 ... Production capacity 14 ... Lead time 15 ... Production capacity adjustment instruction 16 ... Completion date adjustment instruction 17 ... Alternative shop adjustment instruction 18 ... MRP execution instruction 19 ... Problem analysis result 20 ... Problem analysis instruction 21 ... MRP execution result 22 ... Production capacity adjustment result and MRP execution instruction 23 ... Completion date adjustment result and MRP execution instruction 24 ... Alternative shop adjustment result and MRP execution instruction 25 ... Work Quantity calculation instruction 26 ... Work quantity 27 ... Work quantity analysis device 28 ... MRP calculation data 29 ... Lead time prediction instruction 30 ... MRP Open instruction 31 ... Work start order adjustment instruction 32 ... Work start order adjustment result and MRP execution instruction 33 ... Work start order adjustment device 34 ... Production amount adjustment instruction 35 ... Order status 36 ... Delivery reply 37 ... Stock status, production process status 38 ... Manufacturing instruction 39 ... Production amount adjustment result display and MRP execution instruction 40 ... Production amount adjusting device 41 ... "Problem analysis" command menu 42 ... Problem section display table 43 ... Launch start order list 44 ... "Order list" menu 45 ... "Choice"
Menu 46 ... Problem point display table by order number / date 47 ... Detailed information list 48 ... "Details"
Menu 49… “Item list” menu 50… Delayed item list 51… “Adjustment” menu 52… “End”
Button 53 ... Problem route display 54 ... Production capacity display 55 ... Completion date change mode switching menu 56 ... Alternative shop mode switching menu 57 ... Capacity adjustment mode switching menu 58 ... MRP execution instruction mode switching menu 59 ... Production capacity change start time Setting dial 60 ... Production capacity change end point Setting dial 61 ... Production capacity setting dial 62 ... Load situation 63 ... Production capacity line 64 ... Production capacity change start point 65 ... Production capacity change end point 66 ... Production capacity change target section frame 67 ... Problem route display section 68 ... Delay / margin display section 69 ... Completion date change mode switching menu 70 ... Alternative shop mode switching menu 71 ... Capability adjustment mode switching menu 72 ... MRP execution instruction mode switching menu 73 ... Note number change dial 74 ... Completion date change die Al 75 ... Order number display 76 ... Margin display 77 ... Delay display 78 ... Delivery date display 79 ... Delay / margin bar graph 80 ... Problem route display 81 ... Alternative shop display 82 ... Completion date change mode switching menu 83 ... Alternative shop mode switching Menu 84 ... Ability adjustment mode switching menu 85 ... MRP execution instruction mode switching menu 91 ... Overtime setting section 92 ... Overtime cancellation section 93 ... Countermeasure proposal mode switching menu 94 ... Problem route display section 95 ... Countermeasure proposal mode display section 100 ... Countermeasure planning device 101 ... Production plan execution determination device 102 ... Plan deletion instruction 103 ... Plan deletion result and MRP execution instruction 104 ... Plan deletion device 105 ... Countermeasure support instruction 1000 ... Production planning system 1100 ... Order processing system 1200 ... Manufacturing system 1300 ... Expected Production planning system

Claims (10)

[Claims] 1. A manufacturing process of items constituting the completed item is treated as at least one shop for a completion schedule indicating a completion date, quantity, etc. of the completed item requested by a user, and the item in the shop is treated. In the production planning system for calculating the manufacturable period of the above and determining the production schedule until the completion of the finished item, the work capacity provided in the shop, the work capacity and the work load given to the shop, Means for managing the surplus capacity of the shop derived from, and when it is not possible to create a production schedule that satisfies the completion date specified in the completion schedule, from the surplus capacity of the shop, the work required for the item Means for determining the due date that can be secured, and the completion date based on the determined date for each shop. Production planning system, characterized in that it comprises means for calculating an item of producible day. 2. The manufacturing process of the items constituting the completed item is treated as at least one shop with respect to the completion schedule indicating the completion date, quantity, etc. of the completed item requested by the user, and the item in the shop is handled. In the production planning system that calculates the manufacturable period of the above and determines the production schedule until the completion of the finished item, the completion date of the manufactured item is set so that there is no delay in the completion date of each finished item due to the completion schedule. Production plan creation means for setting the work start date of each item as a standard, inventory quantity management means for managing the current stock quantity and future planned stock quantity of each item handled, and the production plan created by the production plan creation means For each item, the relationship between the daily requirement amount, the inventory amount and the planned storage amount is analyzed, and for each shop, the relationship between the daily work amount and the capacity is analyzed. However, if there is a problem in the production plan, the production plan status analysis means that calculates the shortage / amount, the surplus time / amount of the item, the overload time / amount, and the surplus time / amount of the shop. Based on the feature quantity obtained by the production plan status analysis means for the completed finished product lot, the user can take countermeasures by displaying the measure production means for formulating the producible date and the result obtained by the measure production means. A production planning system comprising: a measure proposal presenting means capable of making a decision as to whether or not to implement. 3. The production planning system according to claim 2, wherein the production planning situation analysis means, for items procured from the outside, includes the daily requirement amount in the production plan generated based on the completion schedule. , The daily usable amount given by the means for managing the inventory amount and the planned storage amount,
For items for which a shortage occurs in which the total required amount is larger than the total available amount within a specific period, subtraction calculation is performed sequentially from the present to the future.
A production planning system characterized by calculating the period and amount of surplus for items that will be surplus within the period up to the date of future delivery if the items are currently ordered. 4. The production planning system according to claim 2, wherein the production planning situation analyzing means relates to each manufacturing shop and a daily workload amount after inventory allocation in the production planning generated based on the completion schedule. , The daily capacity is calculated in time series to calculate the period and the workload that the workload is excessive with respect to the capacity of the shop, and the capacity that the workload is less than the capacity of the shop. Production planning system characterized by clarifying the period and the capacity for which there is a margin. 5. The production planning system according to claim 2, wherein the measure planning means is for a finished item lot of which the completion date specified in the completion schedule is changed or for a finished item lot of which additional production is to be performed. With respect to the allocation status of the items constituting the finished product lot or the workload status of the manufacturing shop, each status is a plan change based on various characteristic amounts obtained by the production plan status analysis means according to claims 2 and 3. A production planning system characterized by planning the earliest possible day for the production of the target lot without increasing the problem amount compared to the previous case. 6. The production planning system according to claim 2, wherein the measure proposal presenting means displays the result obtained by the measure planning means according to claim 4 together with other related information. Production planning system. 7. The manufacturing process of the items constituting the completed item is treated as at least one shop with respect to the completion schedule indicating the completion date, quantity, etc. of the completed item requested by the user, and the item in the shop is handled. In the production planning method for calculating the manufacturable period of the above and determining the production schedule until the completion of the finished item, the surplus capacity of the shop is calculated from the work capacity provided in the shop and the workload amount given to the shop. If it is not possible to create a production schedule that satisfies the completion date specified in the completion schedule by managing it as a cumulative value, then determine the date when the necessary work amount for the item can be secured from the cumulative value of the surplus capacity of the shop. The production planning method is characterized by calculating the production available date of the completed item. 8. The production planning method according to claim 7, wherein the item includes an external item to be procured from outside, and the daily usable amount is managed by managing the inventory amount and the planned storage amount of the external item. Then, the daily requirement amount in the production schedule generated based on the completion schedule and the daily available amount are sequentially subtracted from the present to the future, and from the calculation result, the total amount is calculated. For shortage items that have more total requirements than the available amount, calculate the shortage period and the amount, and if you make the current arrangement, total use within the period up to the date of future delivery. For surplus items whose total required amount is less than possible, calculate the period and amount of surplus, and try to change the completion date specified in the completion schedule or to produce additional items. There is a finished item to In this case, based on the calculation result, the allocation status of the items constituting the completed item or the respective workload statuses in the manufacturing shop are changed and the completion is performed without increasing the problem amount compared to before the addition. A production planning method, characterized in that the earliest possible date of production of an item is planned. 9. The production planning method according to claim 7, wherein, for each manufacturing shop, the daily workload amount after inventory allocation in the production schedule generated based on the completion schedule and the daily capacity thereof are set. Calculated by deduction in series, the period when the workload for the capacity of the shop becomes excessive and its workload, and the period when the workload is small and the capacity of the shop exists and its margin If there is a completed item whose capacity is calculated and the completion date specified in the completion schedule is changed, or there is a completed item to be additionally produced, the allocation of the items constituting the completed item is calculated based on the calculation result. It is possible to produce the finished item without the situation or each situation of the workload in the manufacturing shop increasing the problem amount compared to before the change or addition. Production planning method which is characterized in that to develop a longer day. 10. A production planning method, wherein the planning result according to claim 7, 8 and 9 is displayed together with other related information.