JP2003280728A - Production scheduling control method and production scheduling control program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production scheduling control method allowing even an unskilled person to create a production schedule corresponding to small lot multi-production and allow him or her to quickly respond about a delivery date. <P>SOLUTION: In this production scheduling control method, respective data for a customer order and a prospective order are received to store them in a received-order database (DB) 20; the order stored in the received-order DB 20 is divided and processed based on a reference master with data relative to manufacturing resources registered; the divided and processed data are stored in a received-order dividing DB 21; each divided order is subjected to process development based on a unit requirement master to store it in a process development DB 22; an optimum production start date is determined based on the order data subjected to the process development and a production pattern stored in a production pattern DB to pile loads to store the result of the piling of loads in a production plan DB 23; and a process for generating delivery data response data is executed based on the optimum production start date stored in the database 23. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production schedule management method capable of fetching customer orders and prospective orders, registering them in a database, and automatically making a delivery date reply to customers based on various masters and the like. Production schedule management program.

[0002]

2. Description of the Related Art At a manufacturing site for manufacturing products, daily activities are performed based on a production schedule. The production schedule plan is information for systematically implementing production in time for a scheduled delivery date, and is created based on order information such as customer orders and prospective orders and resource information such as processes and equipment. It is something.

[0003]

In recent years, there are demands for high-mix low-volume production at product manufacturing sites.
Compared to the era of small-volume mass production, the content of the production schedule must be complicated. Under these circumstances,
For those who are not skilled in production schedule planning, a considerable burden will be required. In addition, when an order is received from a customer, the customer must give a delivery date response, but the delivery date response must be prompt. As for the work for responding to the delivery date, the more complicated the contents of the production schedule plan, the greater the burden on the unskilled person.

The present invention has been made in view of the above circumstances, and its problem is that even an unskilled person can make a production schedule plan corresponding to mass production of a small variety and promptly give a delivery date answer. It is to provide a production schedule management method and a production schedule management program that can be performed.

In order to solve the above-mentioned problems, a production schedule management method according to the present invention receives a customer order and prospective order information and stores it in an order database, and various manufacturing resources. Based on the reference master in which the information is registered, the order stored in the order database is divided, and the information of each divided order is stored in the order division database, and the order is divided. Then, based on the basic unit master, the process development is performed and stored in the process development database, the process development order information and the production pattern stored in the production pattern database are used to set the optimum production start date. Identify and stack the load,
It is characterized in that the computer executes the processing of storing the result of the load accumulation in the production plan database and the processing of creating the delivery date reply information based on the optimum production start date.

The operation and effect of the production schedule planning management method according to this configuration are as follows. First, we receive each customer information and prospective order information. A customer order is information based on an actual order from a customer, but a prospective order is information to be incorporated in a production schedule plan in anticipation of a future order. The received order is stored in the order database.

The reference master (master file) includes
Various kinds of information serving as a standard for creating a production schedule are stored, and are, for example, information corresponding to the required amount of use of manufacturing resources such as parts, processes, facilities, usage time, and the like. Based on this standard master, the orders stored in the order database are divided. The divided order information is stored in the order division database. Then, the process development process is performed on the divided order based on the basic unit master. The result is stored in the process development database.

Production patterns are stored in the production pattern database. The production pattern is a pattern setting in which order various products are produced. This production pattern is registered in the database in advance based on past production records and the like. The optimum production start date is specified based on this production pattern and the order information in which the process has been developed as described above, and the load is piled up. The result of this load pile is stored in the production plan database. Then, the delivery date reply information can be created based on the optimum production start date.

Each process described above can be realized by a program installed in a computer. Therefore, even a worker who is not skilled in production schedule planning can create and manage the production schedule without a heavy burden. In addition, by making a heap of load based on the optimum production start date, it is possible to make an early delivery date reply. As a result, even unskilled people
It is possible to provide a production schedule planning management method capable of creating a production schedule plan corresponding to small-volume mass production and promptly answering a delivery date.

As a preferred embodiment of the present invention, there is one that performs a process of changing the production schedule plan stored in the production plan database.

The customer may be required to correct the delivery date after the delivery date answer as described above is given to the customer. Therefore, by making it possible to change the production schedule plan with a large amount of load, it is possible to easily respond to a correction request from a customer.

As another preferred embodiment of the present invention, there is one in which the production schedule plan stored in the production plan database and the production record are compared with each other and displayed by the display means.

By comparing and displaying the production schedule and the actual production, the progress of the production schedule and the degree of achievement of the delivery date can be visually and easily confirmed.

As another preferred embodiment of the present invention, the production pattern is set so as to be a repetitive production schedule plan for a certain period, and the delivery date compliance rate of the target product is maximized. I can give you what you have.

By using such a production pattern,
It is possible to give an accurate delivery date reply to the customer.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of a production schedule planning management method according to the present invention will be described with reference to the drawings. Figure 1
It is a figure which shows the structure of the production schedule planning management system for performing a production schedule planning management method.

A large number of personal computers 1 are provided in customers or sales departments. Further, the substance of the production schedule management system 2 is a computer (server), and a management program for constructing the system is installed. The personal computer 1 of the customer or the sales department and the production schedule management system 2 are connected by a network (online ordering system). The form of the network is not limited to a specific one,
It can be constructed using a known infrastructure such as the Internet, a company LAN, a telephone line, and the like. A large number of personal computers 3 are also installed in the production control department and the like, which are also connected by a network.

Customer order information is input by the personal computer 1 provided in the customer or the sales department. The “customer order” is order information from a customer, and is information including, for example, a product (commodity) number, a product name, a delivery date (delivery date), a delivery quantity, a delivery address, and the like.

Prospective order information is input by the personal computer 3 provided in the production control department. The "prospect order" is arrangement information to be incorporated into the production schedule plan in anticipation of temporary inventory in order to equalize and stabilize the production before receiving the order from the customer. This is information that is input in anticipation of future orders, while also considering past order information.

Next, the production schedule management system 2 (hereinafter,
Function of "management system"). The order information entered on PCs 1 and 3 is
Received automatically via the network (order reception function). The management system 2 is composed of a large number of master files, a database, and a schedule editing tool 5. The schedule plan editing tool 5 is software for supporting production schedule planning, and know-how of a skilled person is incorporated in the system logic. In addition, a graphical screen called a Gantt chart is displayed on the computer monitor to facilitate the operator's input work and confirmation work. "Production schedule plan" refers to the schedule of production activities of products or intermediate products for a certain period.

The various masters (master means a master file; the same applies hereinafter) are information corresponding to a ledger such as the required usage amount and usage time of manufacturing resources such as parts, processes, equipment, etc. It is equivalent. This is a file that stores information that is the basis for creating a production schedule. In addition, once created, the master information does not change its contents within a certain period of time. Among the various masters, the product pattern master is registered with information about the product. The products produced based on the production schedule are registered in the product pattern master. When a new product is developed, the maintenance screen of the product pattern master is opened and new registration or correction is performed.

Customer orders are sent in real time via the network. When the customer order information is received, the product pattern master is collated to confirm whether or not the product is registered. Further, other various masters are also collated to perform a determination process as to whether or not the order condition is satisfied.
That is, it is checked whether or not the requirements as order data (whether the product number, delivery date, delivery quantity, delivery address, etc. are provided) are met. If the order condition is satisfied, the customer order information is stored in the order database 20. The prospective order is manually input by the personal computer 3 and similarly stored in the order reception database 20. When a customer order that does not meet the order condition is received, an error message is sent back to the sender.

The customer orders received are the standard production amount for each product set in various masters (production appropriate unit amount).
Based on the above, the order division processing is automatically performed for those exceeding the standard. The customer order with the order division and the customer order without the order division are immediately stored in the order division database 21.

Among the divided customer orders in the order division database 21, intermediate inventory allocation is performed for intermediate product inventory products, and if they can be allocated, the response delivery time is set according to the designated delivery time and the finished lead time. It can be calculated immediately. For division orders for which intermediate inventory cannot be allocated, the unit master is referenced, process development and required amount development are performed, and the process developed order is stored in the process development database 22. Here, the "per-unit master" is a master that defines the physical consumption of raw materials, parts, sub-materials, man-hours, etc. used per unit of product, that is, the physical unit price per unit of product or work. Refers to a file.

Next, the manufacturing lead time is calculated on the basis of the order information that has undergone the process development. Then, the manufacturing start date suitable for the delivery date requested by the customer is calculated, and based on the production pattern information registered in the production pattern database, the optimum production start date is specified and the load is piled up. The result of piled up loads is stored in the production planning database 23. "Load heap" means allocating the amount of work to the necessary processes to manufacture each product and intermediate product.

For example, if the customer order has a delivery date of July 13, 2002 for the product A, the order by process in the process development database 22 will be at regular intervals (several minutes to several minutes).
In the product operation plan date that coincides with the product A registered in the production pattern database 26 in 30 minutes), the date most suitable for the delivery date (planning date + finishing lead time (number of days) is the delivery date (July 13, 2002). (Closest date that does not exceed)) is specified, and if it falls within the operation plan frame, the load is piled up. As a result, delivery date reply information is obtained.

In the above, the "production pattern" will be described. The production pattern defines what product is to be produced in what order among a plurality of products, and is prepared in advance based on the following four requirements. That is, (1) The production schedule is set to be repeated in a certain period. It is usually one week, but can be set to less than one week or more than one week (for example, 6 months). (2) The size of the production frame is set so that the delivery date compliance rate of the target product is maximized. Here, the delivery date compliance rate is an index indicating the degree of achievement of the delivery date requested by the customer, and is represented by the ratio of the quantity that can be manufactured by the delivery date designated by the customer and the total quantity that should be ordered.

(3) The production order is set in consideration of ensuring productivity by reducing the number of setup changes and time at the manufacturing site. For example, a product that uses the same key material
An integrated or continuous production quota. (4) In addition to the above (1)-(3), market such as demand adjustment
Based on the information obtained from the information of customers, companies, etc., it is set assuming the optimal production pattern at that time. According to the method using this production pattern, the system can be efficiently maintained and operated without being affected by changes in production equipment or production conditions.

While paying attention to the above points, the emphasis is placed on the operation focusing on the experience of the person in charge and the latest information on the market. Further, the demand forecast is performed based on, for example, the product shipment record of the past three years. The production pattern is registered in the database so that the person in charge can use the personal computer to satisfy the above requirements. It is also possible to correct / delete the once registered production pattern.

Delivery date information is calculated based on the optimum production start date stored in the above-mentioned production planning database 23.
The created delivery date information is stored in the delivery date reply database 27. The stored delivery date reply information is checked at regular intervals, and if there is untransmitted information, it is extracted and transmitted.
Thereby, the created delivery date reply can be sent to the customer or the sales department by e-mail or the like.

As described above, the order confirmation process, the order division process, the process development process, the load stacking process, the delivery date reply process, and the delivery date reply information transmission process are automatically processed by the software (production schedule planning management program). . Also,
Specify the optimal production start date based on the production pattern information,
Delivery date information can be calculated by carrying out load pile-up. The series of processes described above can be performed within one hour at the maximum. Therefore, it is possible to promptly answer the delivery date to the customer.

FIG. 2 shows a state in which the production schedule plan in which the loads are piled up is changed. In order to change the production schedule plan, the person in charge changes the production schedule plan when the customer requests the delivery date adjustment in response to the automatic delivery date reply to the customer. Based on the contents stored in the production plan database 23, a work instruction database 29 for giving an instruction to a worker on site is created.
On-site work is performed based on this. In addition, the record of the manufacturing work on site is registered in the work record database 28.

On the basis of these databases, it is possible to compare and reference the production schedule and the actual production. This is represented by a Gantt chart screen as shown in FIG. On this screen, operation plans (production patterns) and production schedules on the A production line, B production line, and C production line are shown. In this production pattern, the date and time when the production of a certain product starts and the date and time when the production is scheduled to end are registered.
The numerical values in the lower row of the production schedule column are order quantities (total quantity of customer orders and prospective orders), and the numerical values in the upper row are actual production quantity and production schedule planned quantity. The quantity before accumulating actual results is the production plan quantity. Further, the production pattern registration quantity is displayed in the column of the operation plan. The production pattern registration quantity indicates the standard quantity (calculated based on the basic unit master) that can be manufactured within that time. In this way, since the production schedule plan and the production performance can be visually displayed in comparison with each other, the operator can immediately recognize whether or not the production schedule plan is performed as scheduled.

As described above, the "production pattern" is based on the production schedule plan up to now, taking into account the experience, cans and forecasts, and sales information of the person in charge, to create the production schedule plan and automate the delivery date reply. Can be achieved.

As a known technique similar to the present invention, Japanese Patent Laid-Open No.
There is a production planning scheduling device disclosed in Japanese Patent Publication 1-126221. In this device, the concept of "production allocation pattern" is used. Then, the production allocation pattern storage unit stores the production allocation pattern in which the production order and the production time zone of all products are pre-allocated so that the switching loss and the loss time of the raw materials are minimized. In other words, "Production allocation basic information master"
"Production allocation pattern" is automatically generated, and the order and prospective orders are automatically applied to the "Production allocation pattern".

On the other hand, in the system according to the present invention, the "production pattern" itself is directly input using the Gantt chart screen as shown in FIG.
It has the following advantages over the above known technology.

(1) The experience and policy of the person in charge of editing the production schedule are straightforwardly and easily used as computer data without using an indirect master such as the "production allocation basic information master". Can be generated. As in the known art, a two-stage computer
When configured by logic, it is difficult to automatically create a production schedule that satisfies the editorial staff in terms of the completeness of system logic and the accuracy of input information. Therefore, the system configuration according to the present invention can simplify the system structure and increase the efficiency of system operation.

(2) By using the Gantt chart plan edit screen, the "production pattern" can be directly input / changed. Therefore, the operation efficiency is high. (3) By looking at the Gantt chart plan edit screen and confirming the "production pattern", the image of the "production schedule plan" can be grasped before the order order and the prospective order actually come. (4) Since it is linked to the performance collection system, it is possible to always compare the "production pattern", "production schedule", "production results", "ordered order and prospective order", and easily improve the quality of the "production pattern". It can be carried out.

[Brief description of drawings]

FIG. 1 is a diagram showing a configuration of a system for executing a production schedule planning management method.

FIG. 2 is a diagram showing a system configuration when a production schedule plan is changed.

FIG. 3 is a diagram showing a configuration example of a Gantt chart screen.

[Explanation of symbols]

1,3 PC 2 Production schedule management system 5 schedule editing tool 20 Orders database 21 Order division database 22 Process development database 23 Production Planning Database 24 Various Masters 25 Basic unit master 26 Production pattern database 27 Delivery date response database 28 work results database 29 Work instruction database

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Takeo Yamamoto             1-2 1-2 Shimohozumi, Ibaraki City, Osaka Prefecture Nitto             Electric Works Co., Ltd. (72) Inventor Hirofumi Tateyama             1-2 1-2 Shimohozumi, Ibaraki City, Osaka Prefecture Nitto             Electric Works Co., Ltd. (72) Inventor Yusaku Hirose             1-2 1-2 Shimohozumi, Ibaraki City, Osaka Prefecture Nitto             Electric Works Co., Ltd. F term (reference) 3C100 AA05 AA65 BB12 BB39

Claims (5)

[Claims] 1. An order stored in the order database is divided based on a process of receiving information about customer orders and prospective orders and storing the information in an order database, and a reference master in which various information regarding manufacturing resources is registered. The process of storing each piece of information on the processed and divided orders in the order division database, and the process of developing the divided orders based on the basic unit master and storing them in the process development database. The process of identifying the optimum production start date based on the process-deployed order information and the production pattern stored in the production pattern database, performing load stacking, and storing the result of the load stacking in the production plan database. And a process for creating delivery date reply information based on the optimum production start date, in a computer. Production scheduling management method, characterized in that the execution Ri. 2. The production schedule planning management method according to claim 1, wherein a process of changing a production schedule plan stored in the production plan database is performed. 3. The production schedule planning management method according to claim 1, wherein the production schedule planning stored in the production planning database and the production record are displayed in a state of being compared with each other by the display means. 4. The production pattern is set so that a production schedule is repeated in a certain period and a delivery date compliance rate of a target product is maximized. ~ The production schedule planning management method according to any one of 3 to 3. 5. A production schedule planning management program that causes a computer to execute the production schedule planning management method according to claim 1. Description: