JPH0938848A - Production management system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To set better production conditions by providing a result evaluating part for outputting evaluation information for evaluating output information. SOLUTION: Input information needed for calculation of MRP comprises generally a requirement planning or a production planning 2 of independent demand items, order information 3 already released, inventory information 4, demand information 5 of child parts of released order, and parts table for showing the constitution of parts of the product. Output information comprises order information 8 produced by MRP calculation and demand information 9 corresponding to order information as the basic information. A result evaluating part 10 provides a search function and a calculation function for evaluating if the output result of the MRP calculation is reasonable or not, for example, to provide respective functions as alarm for lack of product, trace of parent item, load alarm, graph of inventory change.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management system applied to a factory for assembling a plurality of parts to manufacture a product, and more particularly to a material requirement planning system.

[0002]

2. Description of the Related Art In recent years, industrial products tend to be more complicated and have higher performance, as so-called system products, in which one product is composed of a combination of parts having various functions, are increasing. Along with this, there is a tendency that both the number of types and the number of parts assembled in one product increase. In such a factory that handles a huge number of parts, production management by computer is indispensable.

In particular, it is indispensable to use a computer to calculate a material requirement plan for determining when and how many parts are required. After that, the material requirement plan was changed to MRP (Material).
alRequirements Planning). A conventional production management system uses a production plan for a product, item information and configuration information indicating a product part configuration, part inventory information, order information, which is information on a part receipt plan, and demand information, which is a part delivery plan information. Was input to perform MRP, and new order information and demand information were output. Since the order information represents the actual result of the parts arrangement, it becomes the plan for the parts to be delivered in the future, that is, the warehousing information. Demand information is required information for lower-order parts required to produce an already released order, and is a delivery plan for inventory.

[0004]

In recent years, in order to keep up with abrupt changes in market trends and innovations in product technology, there is an increasing tendency to frequently change production plans, product component configurations, and the like. Therefore, production cannot proceed according to the initial plan,
There is an increasing need to re-plan the order information by performing MRP recalculation while reflecting the progress of production at any time.

However, the conventional production management system is
The order information, which is the output information of the P calculation, is evaluated, and the input information for generating better order information cannot be adjusted immediately and interactively.

[0006] One of the reasons for this is that the order management and production plan of products, which are the basis of calculation by the conventional production management system, and the item information of parts, the configuration information, the inventory of parts, and the information of stocking / issuing are unique. This is because it can handle only the decided information and does not have a mechanism for changing and recalculating such information. The second reason is that, in the conventional production management system, the calculation time for MRP is generally long for several hours, and there is no time to recalculate in time.

That is, in the conventional production control system, M
The RP calculation input / output information was stored on the magnetic disk, but M
In RP calculation, the data scale of these input / output information is large,
The number of records reaches hundreds of thousands to millions. Further, since the MRP calculation requires frequent data access, the magnetic disk access speed becomes a bottleneck and the processing time becomes long. Usually, the calculation time will be 2 to 10 hours.

Therefore, the parts order and the internal product manufacturing order are released without the feasibility being evaluated sufficiently. Therefore, before the order is released to the parts manufacturer or factory, the production plan or the production order is released. There is a problem that it is not possible to adjust the item information and the configuration information of the parts, which causes a delay in the delivery of the parts and a disturbance such as an excess of the manufacturing load, resulting in a decrease in production efficiency and a delay in delivery.

[0009]

According to the present invention, a material requirement plan is calculated based on input information having product item information and configuration information, product production plan, and parts inventory information, and output having order information and demand information. The production management system for obtaining information is provided with a result evaluation section for outputting evaluation information for evaluating the output information.

The present invention relates to product item information and configuration information,
A material requirement plan is calculated by changing the input information in a production management system that calculates a material requirement plan based on input information including product production plans and parts inventory information and obtains output information including order information and demand information. There is provided a data management unit that keeps the set of input information and the set of output information in correspondence with each other and overlaps them with those before change.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Next, an embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a block diagram showing a production management system according to an embodiment of the present invention. The present embodiment operates on a computer, and the MRP calculation unit 1 and the result evaluation unit 10 may be mounted on the same computer, or may be distributed to a server machine and a client machine connected by a network. good. In this embodiment, it is assumed that the server / client system is used.

First, the MRP calculator 1 will be described in detail. The input information required for the MRP calculation is generally a requirement plan for an independent demand item, that is, a production plan 2, order information 3 which has already been released, inventory information 4, and child parts of the released order. Demand information 5 and a parts table showing the parts configuration of the product are required. BOM is item information 6
And configuration information 7. On the other hand, as output information, MR
Order information 8 generated by P calculation and demand information 9 corresponding to the order information are present as basic information. The MRP calculator 1 reads the input information 2 to 7 and
P calculation is performed, and output information 8 and 9 is written.

In this embodiment, by using a high performance workstation equipped with a large capacity memory, the MR
Input / output information for P calculation is stored in this large-capacity memory to eliminate access time to the magnetic disk device and shorten the MRP processing time to several minutes. Therefore, it is possible to repeat the MRP calculation, which has conventionally been forced to be batch processing, many times.

Next, the result evaluation section 10 will be described.
The result evaluation unit 10 provides a search function and a calculation function for evaluating whether or not the output result of the MRP calculation is appropriate. In this embodiment, the functions of product shortage alarm, parent item trace, load alarm, and inventory transition graph are provided.

FIG. 2 shows an output example of the product shortage alarm.
The order from the present to the delivery date is below the standard lead time, that is, the short delivery date order 14 that is too late to be released at the present time is extracted from the output order information 8 and the item number and order number are extracted. , Display by sorting by each item of delivery date and ordering person code. The user can arbitrarily set the priority of the sort keys (setting of the primary key and secondary key). With this information, the production planner and the person in charge of ordering can immediately search for parts that are likely to be out of stock.

Next, FIG. 3 shows an output example of the parent item trace. When the order of a certain child part is specified, this function presents the production plan order of the product that uses the child part. A display example is shown in FIG. The parts list is reversely expanded to obtain the top-level product, and the lead time from the child parts to the top-level product is summed up and traced back to the lead time to obtain the corresponding production planning order. If the child part is commonly used for multiple products, multiple production planning orders are displayed. As a result, it is possible to grasp the product order that may cause a delay in delivery due to the child parts that are expected to be out of stock.

Next, an output example of the load alarm is shown in FIG. This function extracts and displays products for which the number of orders required based on the order information exceeds the preset standard capability. A day, week, month, etc. can be selected as a mesh for calculating capacity versus load. As a result, it is possible to understand the items that are likely to be delayed due to the excess capacity.

Next, an output example of the inventory transition graph is shown in FIG. The inventory transition graph shows order information 8 and demand information 9
Based on the inventory information 4 and the future inventory quantity transition for each item is calculated and displayed as a graph. Since the excess 16 works as a stocking plan, that is, an increment, and the demand 17 works as a stocking plan, that is, a decrement with respect to the effective stock quantity 18, the effective stock quantity 18 increases or decreases as shown in FIG. By determining whether the quantity of available stock is too large or too small, it is possible to predict the occurrence of excess stock or shortage of parts.

Since the information such as the product out-of-stock alarm by the result evaluation unit 10 is displayed on the screen of the client machine 11, it is possible to inquire at any time when necessary. By utilizing these functions, the validity of the MRP calculation result can be evaluated.

Next, the input information changing unit 13 will be described. The input information changing unit 13 provides a function of changing the input information 2 to 7. For example, the MRP by the result evaluation unit 10
If the evaluation result of is not valid: ・ Delivery date and required quantity of production plan 2 ・ Standard lead time of item information 6 ・ Delivery date and delivery quantity of order information 3 ・ Valid start date and valid end date of configuration information 7 Adjustments can be evaluated to see if better results are obtained. Here, the configuration information 7
The effective date of is a date for designating switching from the A component to the B component when the component is changed due to the design change. An example of the input information change screen is shown in FIG. On this screen,
Change the production volume for each product by specifying the change target period and mesh.

These changes are made by the client machine 11
Since it can be performed on the screen of (1), it is possible to interactively make changes while the result evaluation unit 10 is performing result evaluation.

Next, the data management unit 12 will be described. The data management unit holds the set of input information and the set of output information in association with each other each time the input information is changed and the MRP calculation is executed. For example, version 1 of input information 2 to 7 is version 1 of output information 8 and 9, version 2 of input information is version 2 of output information, and so on. This function allows the person who adjusts the input information to compare and compare the outputs for multiple versions of the input information, so that the input information corresponding to the output information determined to be optimal as a result of the evaluation can be easily input. Can be selected.

Here, it is assumed that, for example, an express train requirement occurs and an event occurs in which the production result of the express train must be interrupted. In the conventional production management system, the production plan 2 to which the express requirement is added is used as the input information of the MRP calculation unit 1, and the obtained result is unilaterally released to the parts manufacturer or factory. On the other hand, the case of this embodiment will be described with reference to FIG. First, the first MRP calculation is performed using the production plan to which the special express requirement is added as input information (version 1). The order information 8 (version 1) of the calculation result is given to the result evaluation section 10
To evaluate. Here, when the shortage alarm as shown in FIG. 2 is obtained, it is necessary to delay the production plan of another product that commonly uses the part.

Therefore, the higher order product of the out-of-stock parts is obtained as shown in FIG. 3, and the input information changing unit 13 is used to delay the production of other products in the higher order product in the production plan 2 for which no express request is required. Create the input information (version 2) changed to. Then, the MRP calculation is re-executed. If it is determined that the obtained version 2 of the order information 8 has less product shortage alarms than the previous version 1 and the result is more appropriate, the version 2 of the input information may be selected. In this way, by repeating the work of MRP execution, result evaluation, and adjustment of input information several times, it is possible to compare output information of a plurality of versions with each other and select the optimum one from them.

As described above, this embodiment uses the MRP calculator,
By combining the result evaluation unit, the data management unit, and the input information change unit, it is possible to immediately evaluate the output information and adjust the input information in an interactive manner. Also, it is possible to compare the data of a plurality of versions with each other and select the optimum input information.

[0027]

The production management system of the present invention outputs the evaluation information of the calculation result of the material requirement plan, so that the validity of the order information and the demand information of the calculation result of the material requirement plan can be promptly judged and is appropriate. If not, the input information is repeatedly changed, the order information is evaluated sufficiently for the feasibility according to the actual production situation, and the input information is less likely to cause problems such as delivery delay of parts or overload of production. Can be selected and released.

Further, each time the input information of the material requirement plan calculation is changed, the set of the input information and the set of the output information are made to correspond to each other and are held in the data management section so as to be overlapped with those before the change. A plurality of sets of input information and output information can be read from the data management unit and displayed, and the input information for obtaining more appropriate output information can be easily selected by comparing these sets.

[Brief description of drawings]

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

FIG. 2 is a diagram showing an output example of a product shortage alarm provided by a result evaluation unit 10 in FIG.

FIG. 3 is a diagram showing an output example of a parent item trace provided by the result evaluation unit 10.

FIG. 4 is a diagram showing an output example of a load alarm provided by the result evaluation unit 10.

FIG. 5 is a diagram showing an output example of an inventory transition graph provided by a result evaluation unit 10.

6 is a diagram showing an example of an input information change screen by an input information change unit 13 of FIG.

FIG. 7 is a flowchart showing a procedure for evaluating a plurality of versions of input information and output information for MRP calculation and selecting an optimum one in the embodiment shown in FIG.

[Explanation of symbols]

 1 MRP calculation part 2 Production plan 3 Order information (input side) 4 Inventory information 5 Demand information (input side) 6 Item information 7 Configuration information 8 Order information (output side) 9 Demand information (output side) 10 Result evaluation part 11 Client Machine 12 Data management unit 13 Input information change unit 14 Short delivery order 16 Order information (bar graph) 17 Demand information (bar graph) 18 Effective stock quantity (line graph)

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Mitsuko Yoshida 5-7-1 Shiba, Minato-ku, Tokyo NEC Corporation

Claims (3)

[Claims] 1. A production management system for calculating a material requirement plan based on input information having product item information and composition information, product production plan and parts inventory information, and obtaining output information having order information and demand information, A production management system including a result evaluation unit for outputting evaluation information for evaluating the output information. 2. The production management system according to claim 1, wherein the evaluation information includes a product shortage alarm, a parent item trace, a load alarm or an inventory transition graph. 3. A production management system for calculating a material requirement plan based on input information having product item information and composition information, product production plan, and parts inventory information, and obtaining output information having order information and demand information, Each time the input information is changed and the material requirement plan is calculated, a set of input information and a set of the output information are associated with each other, and a data management unit for holding the set is duplicated and held. Production control system characterized by.