JPWO2006025082A1 - Method and apparatus for planning the disassembly of recovered products, regeneration plans, product production plans, and procurement plans for product production parts - Google Patents

Abstract

Disassembly plan that minimizes the amount of disassembly work of used products while satisfying a predetermined reuse rate of parts and materials contained in collected used products, and consumption that is consistent with this disassembly plan Provided is a method and apparatus for creating a production and procurement plan so that the sum of costs is minimized. When the scheduled collection quantity of the collected product, the availability date and quantity for each part that can be used by procurement, and the production request quantity that is information on the request date and quantity that require the product are entered The calculation based on the linear programming algorithm is performed based on the predetermined constraint conditions, and the quantity of the decomposition, reproduction, production, and procurement items is output. The constraint condition includes information on the reuse rate and consumption cost of the parts taken out from the collected product.

Description

  The present invention relates to a recovery plan for a collected product, a production plan for a new product, and a procurement plan for parts and materials for a new product. In particular, the utilization rate of recycled parts and materials obtained by disassembling a recovered product is determined. In case of disassembly, regeneration, production, procurement plan.

  People's awareness of environmental issues is increasing year by year, and environmental issues are issues that should be addressed by society as a whole. Under such circumstances, production companies with high awareness of environmental issues are building a system for collecting and reusing products that have finished their life cycle in order to reduce the environmental burden. In addition to these voluntary movements of companies, a ministerial ordinance has already been issued to promote the establishment of a certain reuse rate as a corporate goal for some industrial equipment. The construction of is becoming necessary.

  In addition, among the components included in the collected products, there are components that use substances that place an environmental burden unless proper processing is performed, such as a printed circuit board. Regardless of whether or not such parts are reused, it is desirable to decompose and remove environmentally hazardous substances.

  Conventionally, regarding the use of recycled parts, as a method for determining the order quantity of parts when producing a new product, the number of used products that can be extracted is predicted and extracted from the predicted number of used products. The number of recycled parts that can be calculated is calculated, and the order quantity of the parts is determined based on the calculated number of recycled parts, the number of parts in stock, and the total production plan (for example, Patent Document 1). reference).

  In addition, as a recycling system, there is a recycling system with a plan correction function that can reliably execute a production plan for recycled products even if the quantity of used products collected is shifted against the prediction of the collection time ( For example, see Patent Document 2).

Japanese Patent Laid-Open No. 2002-150083 JP 2002-328976 A

  For example, there are many cases in which a product that has been used and collected may be decomposed and reused as an intermediate product, and the intermediate product may be further decomposed and reused as finer intermediate products or parts. The above-described technology does not take into account the determination of when and to what stage the collected used product is decomposed. That is, there was no feedback from the production plan to the disassembly plan, and all the collected products were assumed to be disassembled. Therefore, there is a possibility that the disassembly work is performed regardless of whether or not the recycled parts after disassembly are scheduled to be used.

  In addition, it is important to satisfy the reuse rate determined in advance and to reuse in the state of the upper intermediate product as much as possible without performing unnecessary disassembly work.

  The present invention has been made in view of these points, and its purpose is to disassemble a used product while satisfying a predetermined reuse rate of parts and materials contained in the collected used product. It is an object of the present invention to provide a disassembly plan that minimizes the amount necessary, and a method and apparatus for creating a production / procurement plan that is consistent with the disassembly plan and that minimizes the sum of consumption costs.

  In addition, since the above-mentioned technology does not consider the usable amount of resources such as facilities and workers, if the production request amount is concentrated in a certain period, production and disassembly work will be performed at the time when the resource shortage was assumed. It may not be possible.

  Therefore, the second object of the present invention is to produce, disassemble, regenerate and procure items (products, intermediate products, products) so that the target reuse rate is satisfied within the scope of resource constraints and the sum of consumption costs is minimized. It is an object of the present invention to provide a planning method and apparatus for calculating the daily quantity of parts.

  In addition, parts that contain substances that cause a burden on the environment if they are not properly treated (hereinafter referred to as “necessary treatment items”) are not reused in the production process, but they must be disassembled.

  Accordingly, a third object of the present invention is to provide a planning method and apparatus for calculating the daily disassembly / regeneration quantity for taking out the necessary processing items.

  In order to solve the above-mentioned problems, the present invention provides information on a scheduled collection quantity of a collected product, an availability date and quantity for each part that can be used by procurement, and a request date and quantity that require the product. When the requested production quantity is input, the calculation based on the linear programming algorithm is performed based on the predetermined constraint conditions, and the quantity of the disassembled, regenerated, produced, and procured items is output. . Restrictions include information on the reuse rate that indicates the percentage of parts used for product production that have been removed from the recovered product and reused, and disassembly, regeneration, and production based on the information on the reuse rate. , Output the quantity of procurement items. In addition, the constraint conditions include information on the cost of disassembling the collected product, the cost consumed in the recycling process, the production of the product, the cost required for procurement of the parts, and the decomposition, recycling, production, Output the quantity of procurement items.

  According to the present invention, it is possible to devise a production / decomposition / regeneration / procurement plan that minimizes the sum of consumption costs while satisfying a given reuse rate (reuse / recycle rate).

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a diagram showing a flow of product production and reuse.

  First, the flow of product production and reuse will be described with reference to FIG.

  In the present embodiment, disassembly and reuse are referred to as reuse, and regeneration and reuse are referred to as recycling, and the term reuse is used as a general term for reuse and recycling.

  A company that produces a product first procures parts necessary for producing the product (101). Then, intermediate products are produced from the procured parts (102), and further intermediate products are produced by combining intermediate products, parts, and materials (103). Then, a product is produced from the intermediate product (104), and the product is shipped (105). The product is delivered to the customer (106). When the product has been used under the customer, the product is collected (107). Then, the collected used products are disassembled from products into intermediate products and parts (108 to 110).

  Here, for reuse, when used in the state of the upper intermediate product (112) taken out by disassembling the product, or when used in the state of the lower intermediate product 113 further disassembled, parts and members (114, 115) May be decomposed and reused for production. An example of disassembling into members is a personal computer housing. Parts made of plastic are once pulverized, melted and regenerated as plastic grains, and parts are regenerated from these grains and reused for production.

  In this way, when the disassembly and regeneration are configured in multiple stages, there is an advantage that the amount of work for disassembly can be reduced if it can be reused as an intermediate product as much as possible. Conversely, if parts are disassembled, there is an advantage that there is a high possibility that they can be reused. In order to perform production that satisfies the target reuse rate while keeping costs down, it is desirable to determine the disassembly and regeneration operations according to the product to be produced.

  The creation of a general production, procurement plan and disassembly / regeneration plan will be described with reference to FIG.

  FIG. 2 is a diagram for explaining the position of a device for creating a product production, a procurement plan, a disassembly of a collected product, and a regeneration plan.

  As shown in FIG. 2, in general, based on a demand forecast 201 of a product to be produced, a production / procurement planning apparatus 202 creates a part procurement, an intermediate product production plan, and a product production plan. Independently of this, a disassembly / regeneration planning device 204 creates a disassembly plan for products and intermediate products, and a regeneration plan for parts based on the used product recovery prediction 203. Because of this configuration, it is not possible to decide how far the recovered product is to be disassembled and how many are to be taken out in accordance with the production situation, and to the state where the recovered product has been determined in advance (a certain intermediate product or part) It was mechanically disassembled and regenerated.

  In the general configuration shown in Fig. 2, the reuse rate (reuse / recycle rate), which is the proportion of parts used in production, is the amount of recycled products in stock at the time of production. It depends. For this reason, the production, procurement plan, disassembly, and regeneration plan are not synchronized, so if the product must be produced with the goal of the reuse rate for environmental measures, etc., a production plan that takes into account the reuse rate is formulated. It's not like that.

  On the other hand, production, procurement plan and disassembly, and creation of a regeneration plan according to an embodiment of the present invention will be described with reference to FIG.

  FIG. 3 is a diagram for explaining the positioning of an apparatus for creating a product, a procurement plan, a disassembly of a collected product, and a regeneration plan according to an embodiment of the present invention.

  As shown in FIG. 3, in this embodiment, based on the demand forecast 201 and the recovery forecast 203 of the product to be produced, a reuse rate target (reuse / recycle rate target) 312 determined, production and procurement, In consideration of the cost 313 consumed by disassembly and regeneration, the disassembly, production, and procurement planning apparatus 300 creates the production and procurement plan and the disassembly and regeneration plan in a consistent manner.

  In the present embodiment, as described above, out of reuse, disassembly and reuse are referred to as reuse, and regeneration and reuse are referred to as recycle. It is assumed that the reuse rate is managed for each reuse and recycling. Even in the case where the reuse rate is managed without distinguishing between reuse and recycling, it can be considered in the present invention.

  In general, there are a plurality of types of products to be collected and products to be produced, and the parts configurations are multi-stage and complicated. Handling an actual product requires a huge amount of processing. In the present embodiment, in order to clearly show the contents of the present invention, the types of products and the parts configuration are simplified and described.

  Next, the configuration of the disassembly, production, and procurement planning apparatus 300 according to this embodiment will be described with reference to FIG.

  FIG. 4 is a diagram for explaining the configuration of the disassembly, production, and procurement planning apparatus in one embodiment of the present invention.

  The disassembly, production, and procurement planning apparatus 300 according to an embodiment of the present invention is roughly divided into three parts: a storage unit that stores input information, a processing unit that performs calculation and outputs a result, and a storage unit that stores the calculation result. It consists of components classified into

  First, the memory | storage part which memorize | stores the 1st input information is demonstrated.

  The storage unit for storing the input information includes a collection schedule storage unit 401, a recycled parts table storage unit 402, an inventory storage unit 403, a warehousing schedule information storage unit 404, a parts table storage unit 405, and a production request storage unit 406. The target recycling rate storage unit 407, the cost information storage unit 408, the compatibility information storage unit 410, the resource information storage unit 413, the resource capability information storage unit 414, and the necessary processing item storage unit 415. Hereinafter, each storage unit will be described.

  The collection schedule storage unit 401 is a storage unit that stores collection schedule information including a scheduled collection date and a quantity for each product. The recycle parts table storage unit 402 is a storage unit that stores the configuration of intermediate products and parts obtained by disassembling / reproducing the collected product and the disassembly lead time or reproduction lead time. The stock storage unit 403 is a storage unit that stores collected products, stock quantities of intermediate products and parts obtained by disassembling / reproducing products, and stock quantities of products to be produced, intermediate products, and procured parts. . The warehousing schedule information storage unit 404 is a storage unit that stores an available date and quantity for each part that can be used by procurement. The parts table storage unit 405 is a storage unit that stores a part configuration and a production lead time for each product. The production request storage unit 406 stores production request information including request dates and quantities that require products. The target reuse rate / target recycling rate storage unit 407 stores the ratio of disassembled parts to be recycled and the ratio of recycled parts. The cost information storage unit 408 stores a cost consumed for disassembling / reproducing the collected product, a cost consumed for producing the product, and a cost consumed for procuring parts. The compatibility information storage unit 410 stores compatibility between intermediate products and parts obtained by disassembling / reproducing the collected product and intermediate products and parts required for producing the product. The resource information storage unit 413 stores the amount of resources such as equipment and people necessary for production, disassembly, and reproduction. The resource capability information storage unit 414 stores the amount of equipment and people that can be used for production, disassembly, and regeneration. The proper processing item storage unit 415 is a storage unit that stores a collected product that needs to be processed properly, and intermediate products and parts obtained by disassembling and reproducing the product.

  Note that the storage units 403, 404, 407, 408, 410, 413, 414, and 415 may be excluded from the configuration when there is no information to be stored in the storage unit.

  Next, a processing unit that performs various calculations will be described.

  The processing unit that performs various calculations includes a plan drafting unit 411 and a plan output unit 412.

  The planning unit 411 calculates daily quantities of items (products, intermediate products, parts) to be produced / disassembled / regenerated / procureed and outputs the calculated quantities to the plan storage unit 409. The plan output unit 412 outputs the production / disassembly / regeneration / procurement plan from the plan storage unit 409 to the output unit.

  Next, a storage unit that stores calculation results will be described.

  The storage unit that stores the calculation result includes a plan storage unit 409.

  The plan storage unit 409 includes a disassembly plan composed of dates and quantities for disassembling products and intermediate products, a regeneration plan composed of dates and quantities for reproducing parts, and a production plan composed of dates and quantities for producing products and intermediate products. This is a storage unit for storing a procurement plan consisting of the required date and quantity of parts that need to be newly procured.

  A storage unit that stores input information, a processing unit that performs calculation and outputs a result, and a storage unit that stores a calculation result may all be mounted on a stand-alone device, or a plurality of devices connected by Ethernet or the like The information may be distributed and installed, and information may be transmitted / received via a network as necessary.

  For example, a storage unit that stores information related to production and procurement is installed in a device managed by the production management department, and stores information related to disassembly and reproduction. Can be mounted on a device managed by the collection department, and the plan planning unit, the plan storage unit, and the plan output unit can be mounted on a device managed by the information department.

  Further, the present invention may be implemented as a program for causing a computer to execute the processing contents of the present invention described below and stored in a computer-readable recording medium.

  Next, the operation of the production / disassembly / regeneration / procurement planning apparatus 300 according to an embodiment of the present invention will be described.

  FIG. 5 is a diagram showing the component configuration, disassembly, and regeneration lead time of the collected product in one embodiment of the present invention.

  In the part configuration tree 1000 shown in FIG. 5, the collected products are indicated by AP + numbers. Further, intermediate products, parts, and materials that can be taken out by disassembling the collected products and intermediate products, parts, and materials below them are indicated by A + numbers. An R + number indicates a recycled product, which is a recycled product that is a combination of recycled products or intermediate products, parts, and materials extracted from the collected products.

  Here, AP01, AP02, and AP03 are the collected products. A table 1001 below the part configuration tree 1000 shows a parent part 1002 to be disassembled, a child part 1003 that can be taken out from the parent part 1002, the number 1004 of child parts 1003 that can be taken out, and a lead time until the child part 1003 is taken out from the parent part 1002. 1005. For example, from AP01, it is shown that A00, A01, A02, and A03 can be disassembled and taken out one unit at a lead time of one day. The reproduction table 1006 below the parent part 1007 to be reproduced, the child parts 1008 necessary for reproducing the parent part 1007, the number 1009 of child parts 1008 necessary for reproduction, and the parent part 1008 to the parent part 1008. A lead time 1010 until the part 1007 is reproduced is shown. For example, 2 units of AP03 and 3 units of A11 are combined to show that R23 can be reproduced with a lead time of 1 day. The data shown in FIG. 5 is stored in the recycled parts table storage unit 402.

  Next, the component configuration of the production product in this embodiment will be described.

  FIG. 6 is a diagram showing the component configuration and production lead time of the production product in the present embodiment.

  In the part configuration tree 1020 shown in FIG. 6, the P + number indicates a product. The i + number indicates an intermediate product, and the B + number indicates a part. A table 1021 under the part configuration tree 1020 includes a parent part 1022 to be produced, a child part 1023 necessary for producing the parent part 1022, a number 1024 of child parts 1023 necessary for production, and a parent part 1023 to a parent part 1023. A lead time 1025 until the part 1022 is produced is shown. For example, the production product P01 is composed of an intermediate product i11 and parts B11 and B12, and the production lead time is one day. The data shown in FIG. 6 is stored in the parts table storage unit 405.

  Returning to FIG. 5 showing the parts table of the recovered product, the part A12 surrounded by the ellipse in FIG. 5 is a reused product that can be reused as the part B12 surrounded by the ellipse of the production product in FIG. P01 can be produced from the intermediate product i11 and the two parts B11 and A12. Similarly, the parts R13 and R23 enclosed by the square in FIG. 5 are recycled products that can be recycled to the parts B13 and B23 enclosed by the square in FIG. 6, respectively. Such compatibility relationship information is stored in the compatibility information storage unit 410. The compatibility relationship information may be 1 to n instead of 1 to 1. For example, when a personal computer is produced and a memory of 128 MB is required, if the capacity is 128 MB or more, there are a plurality of reusable parts.

  The part A03 marked with an underline in the parts table of the collected product in FIG. 5 is not compatible with any part of the production product in FIG. 6, but is designated as an appropriate processing item. This data is stored in the necessary processing item storage unit 415.

  When the amount of resources that can be used per day is limited with respect to the amount of resources required for production, disassembly, regeneration, etc., the resource information storage unit 413 produces, disassembles, Resources required for reproduction and the amount thereof are registered, and the daily usable amount of each resource is registered in the resource capability information storage unit 413.

  Next, cost information is demonstrated using FIG. 7 and FIG.

  In FIG. 7, a table 1030 shows a parent part item 1031 to be disassembled, a child part item 1032 that can be taken out from the parent item 1031, and a disassembly cost 1033 that is consumed in the disassembly work for taking out the child item 1032 from the parent item 1031. Is shown. The table 1034 shows the item 1035 of the recycled product and the recycling cost 1036 consumed when the recycled item 1035 is recycled.

  In FIG. 8, a table 1040 shows a parent part item 1041 to be produced, a child part item 1042 necessary for the production of the parent item 1041, and a production cost 1043 consumed when the child item 1042 is attached to the parent item 1041. Is shown. The table 1044 shows the item 1045 of the procurement item and the procurement cost 1046 consumed when the procurement item 1045 is procured.

  In FIG. 7, the disassembly cost 1033 is a cost required to disassemble the parent item 1031 and take out one unit of the child item 1032. For example, taking two children from one parent doubles the cost. In FIG. 8, the production cost 1043 is a cost required for assembling one unit of the child item 1042 to the parent item 1041. The production cost may be different between when a new product is assembled and when a reusable product is assembled. The cost information shown in FIGS. 7 and 8 is stored in the cost information storage unit 408.

  In the present embodiment, the target reuse rate and the target recycling rate are 20% in total for the products P01 and P02. The target reuse rate and the target recycling rate are set for each product or for each product group in which products are grouped as in this example, and different values can be set for each period. For example, the product P01 can be set to 20% from April 1 to September 30 and 10% from October 1 to March 31. This data is stored in the storage unit 407.

  Next, the collection schedule information will be described.

  FIG. 9 is a diagram illustrating collection schedule information stored in the collection schedule storage unit 401.

  In FIG. 9, a table 1050 shows the collected product 1051 and the inventory quantity 1052 of the collected product 1051. Further, the table 1053 shows the collected product 1054, the scheduled collection quantity 1055 of the collected product 1054, and the scheduled collection date 1056 of the collected product 1054.

  The collected product 1051 is a product that may be decomposed and regenerated. In the example shown in FIG. 9, since the inventory quantity 1052 is “0”, there is no collected inventory. 100 AP01 of the collected product 1054 will be collected on April 11th. Of the data shown in FIG. 9, the collected inventory data (table 1050) is stored in the inventory storage unit 403, and the recovery schedule data (table 1054) is stored in the recovery schedule storage unit 401.

  On the other hand, let's look at the production requirement information next.

  FIG. 10 is a diagram showing inventory information (table 1060), warehousing schedule information (table 1063), and production request information (table 1067).

  A table 1060 shows an item 1061 such as a product or a part necessary for production of the product, and an inventory quantity 1062 of the item 1062. A table 1063 shows items 1064 such as products and parts necessary for production of the product, a planned storage amount 1065 of the item 1064, and a planned storage date 1066 of the item 1064. Table 1067 shows the product 1068, the production request quantity 1069 for the product 1068, and the production request date 1070 for the product 1068.

  In the example shown in FIG. 10, P01 of the product 1068 has 50 production requests on April 7. The stock of the product and the stock of parts required for the production of the product and the planned storage amount are “0”. Of the data shown in FIG. 10, inventory data (table 1060) is stored in the inventory storage unit 403, and scheduled storage data (table 1063) is stored in the storage schedule information storage unit 404, and production request data (table 1067). ) Is stored in the production request storage unit 406. Based on the production request information and the collection schedule information shown in FIG. 7, the planning unit 411 creates a production, disassembly, regeneration, and procurement plan.

  Next, the production, disassembly, regeneration, and procurement plan creation steps in the planning unit 411 will be described.

  The production, disassembly, regeneration, and procurement plan creation steps generally include the following steps 1 to 3.

Step 1: Reading of input information Step 2: Model generation of constraint conditions Step 3: Optimization calculation Processing contents in each step are described below.

First, the processing content of step 1 is as follows.
<Step 1>
Information necessary for calculation is read into the memory from the storage unit storing the input information.

  At this time, if both the inventory and collection schedule data of the products that may be disassembled and reclaimed (referred to as items in the following description) and the production request data are not available, they will be produced, disassembled, regenerated and procured The processing is terminated.

Next, the processing content of step 2 will be described.
<Step 2>
In step 2, a model for input to the optimization calculation in step 3 is generated.

  In the present invention, a linear programming algorithm is used for the optimization calculation. In linear programming, a constraint condition and an objective function are described by a linear equation, and a solution in which the objective function is optimal is searched from a solution set satisfying the constraint condition.

  FIG. 11 is a diagram schematically showing the constraint conditions in one embodiment of the present invention.

  Define daily variables for each item according to their roles. For example, the variables for the item AP01 are the stock amount, the delivery amount, the amount of A01 disassembled from AP01, the disassembly amount of A01, the receipt amount, the stock amount, the exit amount, and the amount of A12 disassembled from A01. “Recovery” and “scheduled entry” shown in a box in FIG. 11 indicate constants input from the storage unit. Characters not enclosed by squares indicate variables.

  In FIG. 11, the flow of things is represented by arrows. Since it is necessary to determine the value of a variable depending on the way of flow of goods, it is necessary to describe an arrow connecting each variable as one constraint condition. The relationship between the arrow and the variable can be described by the following four patterns of constraint conditions.

The first constraint is an inventory constraint.
(1) Stock constraints The stock of items is described by the amount of goods received, the amount of goods delivered, and the expected amount of goods received. For example, regarding A02 in FIG.
t-day stock quantity = t-1 day stock quantity + t day stock quantity + t day stock schedule quantity-t day stock quantity must be satisfied.

The second constraint condition is a component configuration constraint.
(2) Part configuration constraint The parent-child relationship of items is defined as a parent-child relationship as shown in FIGS. Then, for example, to make 1 unit of P01 in FIG. 11, 1 unit of i11 is required 1 day ago.
It is described as production amount on day t of P01 = consumption amount on day t-1 of i11. When consumed by multiple products, such as B11,
B11 consumption on day t = P01 production on day t + 1 + P02 production on day t + 1.

For example, since A01 can be taken out from AP01,
Decomposition amount of AP01 on day t ≧ 1 × t + 1 It is described as the amount of A01 decomposed from AP01 on day 1. Here, in the case of disassembly, since not all child items are taken out from the parent item, it is an inequality.

The third constraint is an allocation constraint.
(3) Provision restrictions Describe what the disassembled and refurbished items can be used for. For example, A02 decomposed from AP01 in FIG. 11 is used as a material for regeneration.
The amount of A02 disassembled from AP01 on day t = the amount of goods received on day t of A02. If the disassembly location and the regeneration location are far apart and it takes days to transport, it is sufficient to offset by that number of days. For example, if transportation takes 3 days,
The amount of A02 disassembled from AP01 on day t = the amount of goods received on day A + t + 3.

The fourth constraint is a production requirement allocation constraint.
(4) Restriction on production requirement allocation Since the amount of product produced satisfies the production requirement, for example, in FIG.
P01 t-day shipment amount = P01 t-day production request amount (S111)
Is described. However, this equality condition does not always hold due to the relationship between the lead time and the recovery amount. Therefore, the shortage of the shipment amount is defined as a variable with respect to the production requirement amount,
P01 t-day shipment amount + P01 t-day shipment unachieved amount = P01 t-day production request amount (S111)
So that the equality condition always holds.

  (1) (2) (3) When the requested production amount (S111) is given by the constraints of (4), the value of the variable can be subordinately determined.

  Next, constraint conditions that are further added to the above four constraint conditions will be described.

When the amount that can be used per day is limited with respect to the amount of resources such as equipment and people necessary for performing production S113, S114, disassembly S115, S116, and regeneration S117, restriction condition (5) Add more.
(5) Resource constraints For example, when production is performed using equipment in production S113,
Equipment occupancy time when 1 unit of i11 is produced x amount of goods received on day t of i11 ≤ equipment operating time on day t. When equipment is shared by a plurality of items, the equipment occupation time of each item × the amount of goods received is added to the left side.

  Next, the target reuse rate and the target recycling rate will be described.

  In the present invention, a target reuse rate and a recycling rate are given as parameters for determining the value of the variable. The reuse rate and the recycling rate are described as follows as the ratio of the amount of decomposition and recycling to the production is allocated to the production.

(Amount of decomposition allocated to production) ÷ (Production volume) = target reuse rate (Amount of recycling allocated to production) ÷ (Production volume) = Target recycling rate “Quantity” to determine the ratio The number may be an amount converted to another standard such as weight. Note that this constraint also does not necessarily match the target amount depending on how the collection amount is given, so define a provision amount that exceeds the target, a provision amount variable that does not meet the target,
(Amount allocated to production for the amount of disassembly-Provision amount exceeding the target + Provision amount less than the target)
÷ (Product production volume) = Target reuse rate.

  Next, an objective function is defined. In the present embodiment, cost, target reuse, recycling rate, and degree of satisfaction of production requirements are used as plan evaluation indexes.

  In this example, the cost can be calculated by multiplying the disassembly amount, the regeneration amount, the production amount, and the procurement amount by the disassembly cost, the regeneration cost, the production cost, and the procurement cost, respectively. As other costs, inventory costs and transportation costs can also be considered. For example, the stock cost may be obtained by multiplying the stock quantity by the stock cost per unit. If the inventory cost is introduced, the result of disassembling and regenerating work according to the production timing can be obtained. The sum of the above costs should be as small as possible.

  The target reuse and recycling rate should be as small as possible in the variable “reserved amount not meeting the target”.

  The sufficiency of the production request may be as small as possible by the variable “unshipment amount”.

  In the present invention, the objective function is the weighted sum of each “must be smaller” variable and mathematical expression.

  When there is an appropriate action item, the amount of receipt of the appropriate action item is multiplied by a negative coefficient and added to the objective function so that the solution is better when the appropriate process item is disassembled.

Next, step 3 will be described.
<Step 3>
In step 3, a solution that minimizes the objective function is obtained from a solution set that satisfies the constraint conditions (= combination pattern of variable values). The model of step 2 (= constraint condition and objective function) is input to the software for solving the linear programming, and the solution is obtained.

  The result (= value of the variable) calculated by the planning unit 411 is output to the plan storage unit 409.

  FIG. 12 is a diagram illustrating the production plan information and the procurement plan information among the calculation result information of the plan planning unit output to the plan storage unit. In FIG. 12, a table 1070 shows the production item 1071, the production amount 1072 of the production item 1071, and the production date 1073 of the production item 1071. Further, the table 1074 shows the procurement item 1075, the procurement amount 1076 of the procurement item 1075, and the procurement date 1077 of the procurement item 1075.

  FIG. 13 is a diagram showing disassembly plan information and regeneration plan information among the calculation result information of the plan planning unit output to the plan storage unit. In FIG. 13, a table 1080 shows a disassembly source item 1081, a disassembly part 1082 that can be taken out from the disassembly source part 1081, a disassembly amount 1083 that indicates the amount of the disassembly part 1082 that can be taken out from the disassembly source part 1081, and a disassembly date 1084. Yes. Further, the table 1085 shows the reproduction item 1086, the reproduction amount 1087 of the reproduction item 1086, and the reproduction date 1088.

  What is output as the production plan information (table 1070) shown in FIG. 12 is the value of the warehousing amount variable immediately after production S113 and S114 in FIG. What is output as the procurement plan information (table 1074) shown in FIG. 12 is the value of the outgoing quantity variable immediately before production S113 in FIG. What is output as the decomposition plan information (table 1080) shown in FIG. 13 is the decomposition amount immediately after decomposition S115 and S116 in FIG. What is output as the reproduction plan information (table 1085) shown in FIG. 13 is the reproduction amount immediately after the reproduction S117 in FIG.

  As information for evaluating the plan result via the plan output unit 412, the calculation result of each cost used for the objective function, the target reuse, the recycling rate, and the plan sufficiency may be output to the plan storage unit 409.

  Alternatively, the values of all variables may be output to the plan storage unit 409 so that the planner can edit and check the plan output unit 412 as necessary. For example, a confirmation method of extracting a stock quantity variable and confirming inventory transition is conceivable.

  Finally, the plan output unit 412 stores the production plan, procurement plan, disassembly plan, and procurement plan stored in the plan storage unit 408 as shown in FIG. 12 and FIG. 13 as paper, display, or electronic data to another system. Output.

  According to the present embodiment described above, it is possible to create a production / decomposition / regeneration / procurement plan that satisfies the reuse / recycle rate target and minimizes the total of production / decomposition / regeneration / procurement costs. In this embodiment, in order to clearly show the characteristic contents of the invention, the types of products and the parts configuration have been simplified. However, there are a plurality of types of products to be collected and products to be produced, and the parts configurations are multistage and complicated. The present invention can be similarly applied to products having various configurations.

It is a figure which shows the flow of production and recycling of a product. It is a figure explaining the positioning of the apparatus which produces production of general products, a procurement plan, decomposition | disassembly of collection | recovery products, and a reproduction | regeneration plan. It is a figure explaining the position of the apparatus which produces the production of a product in one Embodiment which concerns on this invention, a procurement plan, decomposition | disassembly of a collection product, and a reproduction | regeneration plan. It is a figure which shows the structure of the production, decomposition | disassembly, reproduction | regeneration, and procurement plan apparatus in one Embodiment of this invention. It is a figure which shows the components structure and decomposition | disassembly reproduction | regeneration lead time of the collection | recovery product in one Embodiment of this invention. It is a figure which shows the components structure and production lead time of the production product in one Embodiment of this invention. It is a figure which shows the cost information of the cost consumed in the case of a decomposition | disassembly and reproduction | regeneration work. It is a figure which shows the cost information of the production cost consumed in the case of production, and the procurement cost consumed in the case of procurement of components. It is a figure which shows the stock of collection | recovery products, and collection schedule information. It is a figure which shows stock information, warehousing schedule information, and production request information. It is the figure which represented typically the constraints in one Embodiment of this invention. It is a figure which shows the example of an output of the calculation result in a planning part. It is a figure which shows the example of an output of the calculation result in a planning part.

Explanation of symbols

300: Production / Disassembly / Regeneration / Procurement Planning Device Corresponding to Recycling 401: Collection Schedule Storage Unit 402: Recycled Parts Table Storage Unit 403: Inventory Storage Unit 404: Inventory Schedule Information Storage Unit 405: Parts Table Storage Unit 406: Production Request Storage unit 407 Target reuse rate, target recycling rate storage unit 408: Cost information storage unit 409: Plan storage unit 410: Compatibility information storage unit 411: Plan planning unit 412: Plan output unit 413: Resource information storage unit 414: Resource capability Information storage unit 415: Proper processing item storage unit

Claims (12)

It is a planning device for disassembling collected products, recycling plans, product production plans, and procurement plans for parts used in product production,
A recovery schedule information storage unit that stores the planned recovery quantity of recovered products, a storage schedule storage unit that stores the available date and quantity for each part that can be used by procurement, and a calculation based on a linear programming algorithm A plan planning unit that formulates decomposition, regeneration, production, and procurement plan, and a constraint condition storage unit that stores information on a plurality of constraint conditions in calculation in the plan planning unit,
The planning unit is the collection schedule information stored in the collection schedule information storage unit, the warehousing schedule information stored in the warehousing schedule information storage unit, and the information on the request date and quantity that require the product. When a requested amount is input, a plan planning apparatus that outputs the quantity of disassembly, reproduction, production, and procurement items based on the constraint condition information stored in the constraint condition storage unit. The constraint condition storage unit includes information on a reuse rate indicating a proportion of parts that have been taken out from a collected product and reused as a product among parts used for product production,
The planning apparatus according to claim 1, wherein the planning unit outputs a quantity of disassembly, reproduction, production, and procurement items based on information on the reuse rate. The constraint condition storage unit includes information on the cost of the product that is consumed during the decomposition of the collected product, the recycling process, the production of the product, and the procurement of the parts,
The planning device according to claim 2, wherein the planning unit outputs the quantity of disassembly, regeneration, production, and procurement items based on the information on the consumption cost. Disassembly, regeneration, production, procurement planning device according to claim 3,
It further has a resource information storage unit that stores information on equipment and human resources required for disassembly, production, and regeneration processing,
The planning unit further includes a linear equation having a resource available amount as a constraint, and outputs a quantity of decomposition, regeneration, production, and procurement items within the range of the resource constraint. apparatus. Disassembly, regeneration, production, procurement planning device according to claim 3,
It further has an appropriate processing item information storage unit that stores information related to items that require proper processing during the disassembly processing,
The planning unit further outputs disassembly and reproduction quantities for taking out items that require proper processing. A method for planning a disassembly of a collected used product, a recycling plan, a production plan for a product, and a procurement plan for parts used for production of the product,
When the scheduled collection quantity of the collected product, the availability date and quantity for each part that can be used by procurement, and the production request quantity that is information on the request date and quantity that require the product are entered A planning method characterized in that a calculation based on a linear programming algorithm is performed based on a predetermined constraint condition, and the quantity of decomposition, regeneration, production, and procurement items is output. As the constraint condition, information on the reuse rate indicating the proportion of the parts that have been taken out of the collected product and reused as a part of the parts used for the production of the product is included.
The planning method according to claim 6, wherein the quantity of disassembly, regeneration, production, and procurement items is output based on the information on the reuse rate. As the constraint conditions, information on the cost of consumption of the recovered product, the cost of the recycling process, the production of the product, the cost of parts procurement,
The planning method according to claim 7, wherein the quantity of disassembly, regeneration, production, and procurement items is output based on the information on the consumption cost. A planning method according to claim 8, comprising:
As information on equipment and human resources required for disassembly, production, and regeneration processing, the available amount of resources is added as a constraint condition, and the quantity of disassembly, regeneration, production, and procurement items is output within the scope of the resource constraint. How to make a characteristic plan. A planning method according to claim 8, comprising:
It also has information on items that need proper processing during disassembly,
A planning method characterized by further outputting disassembly and recycling quantities for picking up items that require proper processing.   A program for causing a computer to execute the planning method according to any one of claims 6 to 10. A computer-readable storage medium storing a program for causing a computer to execute the planning method according to any one of claims 6 to 10.

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