WO2015056580A1 - 部品棚レイアウト設計装置及びプログラム - Google Patents

部品棚レイアウト設計装置及びプログラム Download PDF

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Publication number
WO2015056580A1
WO2015056580A1 PCT/JP2014/076490 JP2014076490W WO2015056580A1 WO 2015056580 A1 WO2015056580 A1 WO 2015056580A1 JP 2014076490 W JP2014076490 W JP 2014076490W WO 2015056580 A1 WO2015056580 A1 WO 2015056580A1
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Prior art keywords
parts
shelf layout
parts shelf
replenishment
layout
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Ceased
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PCT/JP2014/076490
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English (en)
French (fr)
Japanese (ja)
Inventor
聡士 永原
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Hitachi Ltd
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Hitachi Ltd
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Priority to US15/029,793 priority Critical patent/US20160253611A1/en
Publication of WO2015056580A1 publication Critical patent/WO2015056580A1/ja
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    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G06Q10/063—Operations research, analysis or management
    • G06Q10/0631—Resource planning, allocation, distributing or scheduling for enterprises or organisations
    • G06Q10/06313—Resource planning in a project environment
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
    • G06Q10/087—Inventory or stock management, e.g. order filling, procurement or balancing against orders
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q30/00—Commerce
    • G06Q30/06—Buying, selling or leasing transactions
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management

Definitions

  • the present invention relates to a parts shelf layout design of a warehouse at a manufacturing / distribution site.
  • picking work As a typical example of a work for unloading desired parts from a warehouse.
  • picking work there is a method in which an operator collects specified parts while going around a parts shelf.
  • this method in order to efficiently perform the picking work, it is important to optimize the arrangement of the parts shelves in the picking area.
  • the determination of the component shelf arrangement as described above is called a component shelf layout design.
  • Patent Document 1 Conventionally, as a parts shelf layout design method aiming at picking work efficiency improvement, for example, as disclosed in Patent Document 1, there is a method of determining the placement of parts shelves in accordance with the delivery frequency of each part.
  • a layout change instruction is issued so that a part with a high delivery frequency is arranged near the reference position and a part with a low delivery frequency is arranged far from the reference position.
  • the conventional parts shelf layout design method such as Patent Document 1 focuses on only the cyclic movement distance at the time of picking, and aims to improve the picking work efficiency.
  • the parts inventory in the parts shelf decreases, it is necessary to replenish parts from the backward storage shelf where the parts are stored to the parts shelf in the picking area.
  • Picking work is interrupted when the parts inventory in the parts shelf runs out (out of stock), so it is important to replenish so that no shortage occurs in order to improve picking work efficiency.
  • a method of replenishing parts to a preset number of parts is common.
  • the frequency of occurrence of replenishment work is determined by the size of the parts shelf to which each part is assigned. For example, the larger the component shelf of the component, the larger the replenishment amount can be set. Therefore, more components can be replenished in one replenishment operation, and the frequency of occurrence of the replenishment operation is reduced.
  • the occurrence frequency of the replenishment work is reduced, it is possible to suppress the occurrence of a shortage due to the delay of the replenishment work.
  • the present invention includes, for example, a storage unit and a control unit, and the storage unit includes picking work record information including information on the amount of goods delivered for each component, and information on the distance between each component shelf. And information on the distance between the parts shelves including the parts shelf and the parts shelf layout information indicating the capacity of the parts assigned to the parts shelves and the parts shelves.
  • a picking movement distance calculating unit that calculates a moving distance; a replenishment occurrence frequency calculating unit that calculates a frequency of occurrence of replenishment work using information in the storage unit; and generating a plurality of new parts shelf layout plans,
  • a new parts shelf layout generation unit to be added to the layout information, and the picking movement distance calculation unit and the replenishment occurrence frequency calculation unit include the current parts shelf layout and the new parts shelf layout. Calculate the picking movement distance and the occurrence frequency of the replenishment work for the parts shelf layout plan generated by the auto generation unit, and select the part shelf layout plan that satisfies a predetermined condition from the parts shelf layout plan generated by the new parts shelf layout generation unit. And an optimum parts shelf layout extracting unit to be extracted.
  • a user of this apparatus can determine a parts shelf layout that achieves both efficiency of picking work and suppression of replenishment work.
  • Fig. 3 is a schematic diagram of the picking operation. As shown in FIG. 3, there are a plurality of parts shelves in the picking area, and parts are arranged in each part shelf. Then, the picking operator starts from the picking start point, collects a plurality of parts while going around the picking area, and moves to the picking end point after completing the collection of all the instructed parts. Further, the replenishment operator replenishes the parts from the backward storage shelf so that the stock amount of the parts shelf becomes the set replenishment amount when the stock amount of each parts shelf falls below the replenishment point.
  • the parts shelf layout design apparatus provides a user with a parts shelf layout change plan that takes into account both the reduction of picking movement distance and the suppression of replenishment work, for example, for the above-described work.
  • Fig. 1 is a functional block diagram of the parts shelf layout proposal design device.
  • the parts shelf layout plan designing apparatus includes a storage unit 110, a control unit 120, a display unit 130, and a communication unit 140.
  • the storage unit 110 includes a picking work result information storage area 111, a part / part shelf assignment availability information storage area 112, a part shelf distance information storage area 113, a parts shelf layout information storage area 114, and a parts shelf layout change point information storage area 115. , A picking work information storage area 116, a supplementary work information storage area 117, and a parameter information storage area 118.
  • the picking work result information storage area 111 stores information for specifying past picking work results.
  • a picking work record information table as shown in FIG. 4 is stored.
  • the picking work record information table has a round number field 111a, a part name field 111b, a delivery amount field 111c, and a work date and time field 111d.
  • the round number column stores information for specifying the round number.
  • the round means a series of operations starting from the picking start point, traveling around the parts shelf, collecting all instructed parts, and arriving at the picking end point.
  • the round number is a unique value for the above series of operations.
  • the part name column stores information for identifying the part name.
  • In the output amount column information specifying the number of collected parts in the round is stored.
  • the work date / time column information for identifying the actual date / time when the part has been collected in the round is stored.
  • the part / part shelf allocation availability information storage area 112 stores information for specifying whether each part can be assigned to each part shelf.
  • a part / part shelf allocation availability information table as shown in FIG. 5 is stored.
  • the parts / parts shelf assignment availability information table has a part name column 112a, a parts shelf name column 112b, an assignment availability column 112c, a supplement point column 112d, and a supplement amount column 112e.
  • the part name column stores information for identifying the part name.
  • the parts shelf name column information specifying the parts shelf name is stored.
  • the assignment availability column information specifying whether or not the part can be assigned to the parts shelf is stored.
  • replenishment point column and the replenishment amount column information specifying the replenishment point and the replenishment amount when the part is allocated to the parts shelf is stored.
  • This table can be created based on the size of parts and various on-site restrictions. For example, when the component size is larger than the component shelf size, it can be set that assignment is impossible. Further, the replenishment amount of the part with respect to the part shelf can be calculated from the width / height / depth of the cardboard in which the parts are packed and the width / height / depth of the part shelf.
  • the part shelf distance information storage area 113 stores information for specifying the distance between a part shelf and another part shelf.
  • a part shelf distance information table as shown in FIG. 6 is stored.
  • the inter-part shelf distance information table has a start part parts shelf name field 113a, an end part parts shelf name field 113b, and a distance field 113c.
  • the start part shelf name field and the end part shelf name field information for identifying the parts shelf name is stored.
  • the distance field stores information for specifying the distance from the start point component shelf to the end point component shelf.
  • the distance information stored in the distance column is not necessarily the linear distance between the shelves, but is the distance of the movement path when moving from the start point component shelf to the end point component shelf during picking work.
  • this table also stores distance information from each part shelf to the picking work end point and from each part shelf to the picking work end point.
  • the component shelf distance information table is stored assuming that the component shelf arrangement itself is fixed, but when changing the component shelf arrangement, the component shelf distance information table is updated. It is possible to apply the present invention.
  • the parts shelf layout information storage area 114 stores information for specifying the parts shelf layout.
  • the component shelf layout does not mean an arrangement location or an arrangement form of each component shelf, but specifies which component is assigned to each component shelf.
  • a parts shelf layout information table as shown in FIG. 7 is stored.
  • the parts shelf layout information table has a layout name field 114a, a parts shelf name field 114b, an assigned parts name field 114c, a replenishment point field 114d, and a replenishment amount field 114e.
  • the layout name column information specifying the parts shelf layout name is stored.
  • the parts shelf name column information specifying the parts shelf name is stored.
  • the replenishment point field and the replenishment amount field are related to the capacity of the parts shelf, and store information specifying the replenishment point and the replenishment amount of the part in the parts shelf when the parts are assigned to the parts shelf. .
  • the parts shelf layout change point information storage area 115 stores information for specifying a part assignment change point when changing from one layout to another, which is a processing result of a part shelf layout change point extraction unit described later.
  • a parts shelf layout change point information table as shown in FIG. 8 is stored.
  • the parts shelf layout change point information table includes a layout name field 115a before change, a layout name field 115b after change, a part name field 115c, a part shelf name field 115d before change, and a part shelf name field 115e after change.
  • a post-change replenishment point column 115f and a post-change replenishment amount column 115g is stored.
  • the part name column stores information for identifying the part name.
  • information for specifying the part shelf name to which the parts are assigned in the pre-change layout is stored.
  • post-change assigned parts shelf name column information specifying the name of the parts shelf to which the parts are assigned in the post-change layout is stored.
  • post-change replenishment point column and the post-change replenishment amount column information specifying the replenishment point and the replenishment amount of the part in the parts shelf in the post-change layout is stored.
  • the picking work information storage area 116 stores information for specifying the movement distance of each round of the picking work, which is the processing result of the picking movement distance calculation unit described later.
  • a picking work information table as shown in FIG. 9 is stored.
  • the picking work information table has a round number column 116a and a movement distance column 116b.
  • the round number column stores information for specifying the round number.
  • the movement distance column stores information for specifying the movement distance in the round.
  • the replenishment work information storage area 117 stores information specifying the number of replenishment work occurrences for each part on each day, which is the processing result of a replenishment occurrence frequency calculation unit described later.
  • a replenishment work information table as shown in FIG. 10 is stored.
  • the replenishment work information table has a date column 117a, a component name column 117b, a component shelf name column 117c, and a replenishment occurrence frequency column 117d.
  • the date column information specifying the date is stored.
  • the part name column stores information for identifying the part name.
  • the parts shelf name column information specifying the parts shelf name is stored.
  • the replenishment occurrence frequency column information for specifying the number of times the replenishment of the part in the part shelf occurs on the date is stored.
  • the parameter information storage area 118 stores information for specifying the item and value of each parameter that has been input on the display unit described later.
  • a parameter information table as shown in FIG. 11 is stored.
  • the parameter information table has an item column 118a and a value column 118b.
  • the item field stores information for specifying the parameter item.
  • the value column stores information for specifying the value of the item.
  • control unit 120 includes a new parts shelf layout generation unit 121, a picking movement distance calculation unit 122, a replenishment occurrence frequency calculation unit 123, an optimum parts shelf layout extraction unit 124, and a parts shelf layout change point extraction unit 125. .
  • the new parts shelf layout generation unit 121 performs a process of generating a new parts shelf layout plan using the parts shelf layout information, the parts / parts shelf assignment availability information, and the part shelf distance information in the storage unit. For example, in the present embodiment, a new parts shelf layout plan is generated by replacing the assigned parts shelves of any two parts using the current state or new parts shelf layout information. Information on the generated parts shelf layout plan is stored in the new parts shelf layout information.
  • the picking movement distance calculation unit 122 performs processing for calculating the picking movement distance in each component shelf layout, using the picking work result information, the part shelf distance information, and the component shelf layout information in the storage unit. Details of this processing will be described later.
  • the replenishment occurrence frequency calculation unit 123 performs a process of calculating the replenishment operation occurrence frequency in each component shelf layout using the picking work result information and the component shelf layout information in the storage unit. Details of this processing will be described later.
  • the optimum parts shelf layout extraction unit 124 extracts the optimum parts shelf layout from the parts shelf layout plan generated by the new parts shelf layout generation unit using the picking work information and the supplementary work information stored in the storage unit. Process. Details of this processing will be described later.
  • the component shelf layout change point extraction unit 125 uses the component shelf layout extracted by the optimum component shelf layout extraction unit to extract a layout change point when changing from the current component shelf layout to the optimum component shelf layout. I do. Details of this processing will be described later.
  • the display unit 130 outputs the information stored in the storage unit 110.
  • the display unit 130 performs processing for displaying information in the parts shelf layout change point information storage area 115 of the storage unit 110.
  • the communication unit 140 transmits and receives information via a network.
  • FIG. 2 is a schematic diagram of a parts shelf layout design system according to an embodiment of the present invention.
  • the parts shelf layout design system includes a parts shelf layout design device 210, a picking work result management device 220, and a parts shelf layout change instruction device 230, which transmit and receive information to and from each other via a network 240. Can do.
  • the picking work result management apparatus 220 receives input from the information terminal used in the picking work and manages the picking work result information. Then, the picking work result information is transmitted to the parts shelf layout design device at a predetermined time or in response to a request from the parts shelf layout design device, and the parts shelf layout design device stores this information in the picking work result information storage area. To remember.
  • the parts shelf layout change instruction device 230 manages the assignment change instruction information of each part to each parts shelf.
  • the information of the parts shelf layout change point information storage area is received from the parts shelf layout design device at a predetermined time or in response to a request from the parts shelf layout design device.
  • FIG. 12 is a processing flowchart example of the parts shelf layout design apparatus.
  • the embodiment of the present invention will be described in detail with reference to FIG.
  • step S100 the performance information of each round used for parts shelf layout evaluation is extracted from the picking work performance information table. Specifically, round result information is extracted in which the value of the work date and time column of the picking work result information table is included in the evaluation target start date and evaluation target end date of the parameter information table.
  • step S200 from the parts shelf layout information table to obtain the parts shelf layout L 0 is.
  • the picking movement distance calculation process is a process of the picking movement distance calculation unit of the control unit.
  • picking moving distance calculating firstly, for each round it was extracted with step S100, the picking target components and parts shelf layout L 0 of the round, to extract the component shelf group of the cyclic target. Then, the circulation order of the parts shelf group is determined, and the movement distance is calculated from the circulation order and the distance information between the parts shelves. Finally, the calculated value is stored in the picking work information table as the movement distance of the round.
  • the parts shelf Shelf1 closest to the picking start point is visited first, and the parts shelf Shelf2 closest to Shelf1 is visited second.
  • the present invention is as described above. The method is not limited.
  • the replenishment occurrence frequency calculation is a process of the replenishment occurrence frequency calculation unit of the control unit.
  • the transition of the parts inventory in the parts shelf with the passage of time is simulated using the outgoing quantity of each part at each date and time extracted in step S100.
  • the replenishment work occurs when the parts inventory falls below the replenishment point, the parts inventory is raised to the replenishment amount.
  • the number of occurrences of supplementary work is totaled, and the processing results are stored in the supplementary work information table.
  • Step S400 is a process of the new parts shelf layout generation unit of the control unit, and generates a new parts shelf layout.
  • the parts shelf layout L n is generated by changing a part of the parts shelf layout L 0 to L n ⁇ 1 .
  • there are the following two methods for changing Either one may be used, or both may be applied alternately.
  • step S500 the parts shelf layout L n generated in step S104, calculates the picking movement distance and replenishment occurrences.
  • the details of this process are the same as in step S300, and thus the description is omitted.
  • step S600 from the parts shelf layout L 0 ⁇ L N, it extracts the optimal component shelf layout L Opt.
  • an extraction method for example, a method of extracting a parts shelf layout in which the weighted sum of the picking movement distance and the number of replenishment occurrences is minimized, or a part shelf layout in which the picking movement distance is equal to or less than a threshold and the number of occurrences of replenishment is minimized And a method of extracting a parts shelf layout in which the number of replenishment occurrences is equal to or less than a threshold and the picking movement distance is minimum.
  • Each extraction condition and each threshold value can be set by the user.
  • step S700 when changing from the current part rack layout L 0 optimally parts shelves layout L Opt, it extracts the layout changes.
  • This process is a process of the parts shelf layout change point extraction unit of the control unit. In this process, parts groups with different assigned parts shelves in L 0 and L Opt are extracted, and information such as parts shelf names before and after the layout change is stored in the parts shelf layout change point information table.
  • FIG. 13 and 14 are schematic diagrams showing examples of display screens.
  • FIG. 13 shows an input / display screen for setting information to be stored in the storage unit.
  • the screen has, for example, each data file path input / display area 131 and parameter input / display area 132.
  • the picking work result data the part / part shelf allocation availability data, the part shelf distance data, and the current parts shelf layout data, data created by the user or data stored in an external storage device is read.
  • the picking work result data not only past result data but also future prediction data may be read.
  • the evaluation target period can be specified.
  • the evaluation target period may be specified in consideration of the frequency of changing the layout.
  • the 14 is a display screen for displaying information of the picking work information storage area, the replenishment work information storage area, and the parts shelf layout change point storage area of the storage unit.
  • the screen is, for example, picking movement of each layout plan It has a layout evaluation result display area 133 for displaying the evaluation results of the distance and the number of occurrences of replenishment, and a parts shelf layout change point display area 134 for displaying a change point for changing from the current layout to the optimum layout. Further, for example, when each point on the layout evaluation result display screen is selected, the display screen may display a change point for realizing a layout corresponding to the point in the parts shelf layout change point display area. Good.
  • the past picking work results are used to calculate evaluation values such as the movement distance and the number of replenishment occurrences in each component shelf layout plan. It is also possible to predict the amount of goods delivered for each product in each round and calculate the evaluation value using the prediction result.
  • the picking movement distance is used as the evaluation value.
  • the picking movement distance is calculated using information on the movement speed of the worker and the work time when picking each product from each component shelf.
  • the part may convert the picking movement distance into picking work time.
  • the replenishment occurrence frequency calculation unit may convert the number of replenishment occurrences into the replenishment work time using information on the work time necessary for replenishing each product to each product shelf. Then, the optimum parts shelf layout extraction unit can extract a parts shelf layout plan in which the picking work time and the replenishment work time are shortened compared to the current parts shelf layout and a parts shelf layout plan in which the total time is the shortest.
  • Each of the above-described configurations, functions, control units, storage units, and the like may be realized in hardware by designing a part or all of them, for example, with an integrated circuit.
  • Each of the above-described configurations, functions, and the like may be realized by software by interpreting and executing a program that realizes each function by the processor.
  • Information such as programs, tables, and files that realize each function can be stored in a memory, a recording device such as a hard disk or an SSD (Solid State Drive), or a storage medium such as an IC card, an SD card, or a DVD.

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PCT/JP2014/076490 2013-10-16 2014-10-03 部品棚レイアウト設計装置及びプログラム Ceased WO2015056580A1 (ja)

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