JP2010055258A - Method for supporting improvement in supply chain efficiency - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for supporting improvement in supply chain efficiency enhancement of a supply chain for preventing a production delay due to lack of materials and a delivery delay due to deficiency in a product inventory even when a sales plan fluctuates greatly beyond a previous assumption and for minimizing waste loss of dedicated materials in change to a succeeding product when a product life is terminated. <P>SOLUTION: A safe inventory quantity and procurement conditions causing no shortage of the product and minimizing the waste loss of the product and the dedicated materials at an EOL (End OF Life) are calculated by estimating extended sales fluctuation greater than the previous assumption, performing demand forecasting in the remaining life cycle of the product, and performing simulation in a supply chain model based on demand information, an inventory of the dedicated materials including an inventory of the product and an inventory at suppliers, a material unit price by the number of ordering lots of dedicated components, a material delivery lead time, and a physical distribution route. Furthermore, this simulation is carried out by a predetermined cycle/period on the life cycle of the product. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention does not interfere with the sales plan even if the sales plan fluctuates in the supply chain from the procurement of the material to the customer through the production process, and occurs at the end of the product life cycle. The present invention relates to a supply chain chain efficiency support method capable of reducing material disposal loss.

  By the time a product arrives at a customer, multiple operations from the procurement of materials including raw materials (hereinafter also referred to as parts) to delivery to the customer, for example, various operations such as material procurement, production and sales (hereinafter also referred to as departments) A series of business activities are performed through coordination of business activities in each business.

  The business is not always limited to one site, and is generally composed of a plurality of sites. For example, the sales department is often composed of a plurality of sales bases.

  Optimization of such a chain of business activities, the so-called supply chain (efficiency) has been studied as an important issue.

  When optimizing a supply chain where there are multiple operations, consider production information such as production volume and delivery date, procurement, production, distribution, sales, etc., and information about their bases from multiple perspectives. It becomes necessary to do. Such a thing is generally called supply chain management (SCM).

  For this reason, in order to optimize the supply chain, a method for creating a supply chain model on a computer and simulating with a simulator to optimize the supply chain has been developed.

  In the supply chain, if there are weak parts in the chain, such as the flow of information and information, such as unclear stock quantity, the supply chain may be broken. Therefore, in order to optimize the flow of materials and information on business activities such as procurement, production, and sales of materials from the procurement of materials to delivery to customers, the flow of materials in all operations in the supply chain Need to be captured. Therefore, introduction of an information system package called an ERP (Enterprise Resource Planning) package has been promoted for the core business of a company.

  The ERP package is an integrated business package, which is package software for an enterprise information system that integrates the entire enterprise activities such as sales, production, logistics, and finance. It is intended to integrate systems built separately in each department so that they can be referred to and used by each department. Centralized management of data such as financial accounting and personnel, system upgrades and easy maintenance inspections, etc. It is possible to refer to the work of the department in real time.

  In the supply chain, sales and production plans are prepared in response to orders from customers, and materials are procured from the outside or other material suppliers (hereinafter referred to as suppliers), and production activities are carried out in the production process. .

  FIG. 1 is a schematic diagram illustrating an example of a supply chain. In FIG. 1, a customer 21 places an order for a product at a sales base 22 where the product is purchased. The sales base 22 creates a sales plan based on the order from the customer 21 and the sales forecast at the sales base 22 and places an order with the sales department 23. Here, the sales base 22 refers to a sales department in a sales department of a manufacturing company that produces a product, and a sales company such as a distributor or an agency independent of the manufacturing company.

  The sales department 23 creates a demand plan based on orders from a plurality of sales bases 22, an inventory plan in the sales department 23, and orders products from the production department 24. Here, the sales department 23 has a business that supervises orders, entry / exit information, sales information, and the like from each sales base, and has a base warehouse 42 that temporarily stocks products. The sales department 23 is often a department of the manufacturing company. A plurality of sales departments 23 may be provided for each region, for example, for each city, prefecture, etc. in the country, and for each state, county, etc. outside the country.

  The production department 24 considers the factory inventory of products and materials based on the demand plan from the sales department 23, decides the shipment of products, the production quantity at the factory, and orders the materials from the material procurement department 25. The material ordering department orders materials from a plurality of suppliers 26 and procures materials. In FIG. 1, solid arrows indicate the flow of information such as orders, and broken arrows indicate the flow of goods.

  When placing an order for the product, in general, in addition to the order confirmation information for the product, the procurement side (ordering side) notifies future supply information (forecast information) from the procurement side (ordering side) to the supply side. The forecast information is changed to product order confirmation information (confirmation information) on a predetermined date. As a result, the supply side can make a future production plan, and it is possible to suppress the occurrence of excess inventory and shortage. In the example of FIG. 1, sales prospect information and sales confirmation information from the sales base to the sales department are demand forecast information and demand confirmation information from the sales department to the production department.

  However, orders from customers do not always stay constant, and sales plans may vary. This causes demand and production plan fluctuations when changing from forecast information to confirmed information.

  The so-called product life cycle from the start of sales to the end of sales is generally considered to go through the stages of introduction, growth, maturity, and decline. During the decline period, the amount of demand decreases, and the product life in the product life cycle ends, that is, the end of product production, so-called End Of Life (hereinafter also abbreviated as EOL).

  Here, in the end of production and sales of conventional products (hereinafter also referred to as EOL products), in many cases, production and sales of successor products that are successors of the EOL products are started, and the EOL products become the successor products. Can be switched. However, since the successor product is a new product, the production start time may fluctuate from the original plan due to the sales strategy, production, quality, etc. (in many cases, it will be delayed). For this reason, there are fluctuations in sales and production of successor products, and there may be fluctuations in sales and production of EOL products. In this way, fluctuations in sales and production also occur when the product is switched from the EOL product to the successor product.

  For this reason, it is possible to prevent delays in production due to shortage of materials with long delivery lead times, so-called long delivery parts, and delays in shipment due to shortages of products, especially against fluctuations in sales plans. Materials and product inventory that can be minimized are desired.

  In addition, the materials at the time of EOL of the EOL product, in particular, the dedicated materials for the product and the stock of the product remain as surplus stock and are discarded to cause a disposal loss. For this reason, reduction of the waste loss is desired.

  In contrast to the above, calculating the error of the past forecast information, the average value of the error, and the standard deviation of the error from the past forecast information and the order received corresponding thereto, and correcting the current forecast information The calculation of the order quantity is disclosed. (For example, refer to Patent Document 1).

  In addition, it is disclosed that a supply chain model is evaluated based on an evaluation index, an optimal supply chain model is set, and an optimal supply chain is constructed based on the optimal supply chain model (see, for example, Patent Document 2).

In addition, the computer obtains time information including the time of manufacture or start of use of the product used by the customer, compares the demand forecast period with the obtained time information, and the product life expectancy comes during the demand forecast period Extracting a product is disclosed (for example, refer to Patent Document 3).
JP 2006-39802 A JP 2007-226718 A JP 2004-30002 A

  Patent Document 1 corrects the current forecast information and calculates the order quantity, so that the order receiving side can make a highly accurate order prediction, thereby preventing the occurrence of shortage and excessive inventory. It is intended to effectively suppress. However, in the case of a sudden change in order, it is impossible to predict whether or not a shortage will occur, and a shortage may occur.

  Patent Document 2 describes the procurement, production, distribution, and sales of materials (parts) from the procurement of an operating supply chain to delivery to consumers by performing a simulation using the form of the operating supply chain as a supply chain model. It optimizes the flow of business activities and information. However, the response to changes in sales and demand is not considered.

  Patent Document 3 provides a demand prediction method with excellent accuracy and efficiency for producing economically in a timely manner in accordance with the required amount. However, there was no mention of adjustment of material inventory in the production department, and there was a risk that material inventory would become excessive.

  Conventionally, in order to cope with a sudden increase in orders for products more than expected, it has been generally performed to have a large number of products and materials in stock. Such a sudden increase in product orders may occur when the product is switched from the EOL product to the successor product. For example, when the production start time of the successor product is delayed with respect to the original plan, the production of the EOL product may be increased and connected to the successor product. In many cases, the delay in the production start time of the successor product is unexpected, and therefore the production increase of the EOL product is often sudden.

  As described above, if a method for increasing the number of stocks is used, the delivery delay of the product can be reduced. However, the material procurement department has a large safety stock for materials (parts) having a long delivery lead time, so-called long delivery parts. In the production department, products with a long production lead time will have a lot of work-in-process and products as safety stock in the process. On the other hand, the sales department will have the product as a safety stock as a countermeasure when the product delivery time is delayed due to a material shortage in the production department. In this way, each department in the supply chain has a safety stock in a form corresponding to each department, and the entire supply chain often has an excessive number of inventory. In general, there are many parts with long delivery times, such as electronic parts, which have a high unit price, and as a result, inventory costs increase and the state may be maintained.

  Here, if the increase in orders from the sales base is more than expected, and if the delivery date is sufficient to be able to handle the procurement from the production department, the safety stock in the sales department mentioned above is the expected safety stock. There is no problem with this, but in general there are many cases where a normal delivery date is used. For this reason, the above-mentioned safety stock in the sales department increased due to sales fluctuations in addition to the quantity corresponding to the difference between the delivery lead time (LT) and the distribution lead time (LT) in procurement from the production department and the delivery date. Often the quantity takes into account minutes.

  The shipping LT is the time (days) from when the sales department places an order to the production department and the product is shipped from the production department. The logistics LT is the product is shipped from the production department and received at the sales department (base warehouse). This is the time (number of days) to complete. Also, the quantity corresponding to the difference between the sum of the shipping LT and the logistics LT and the delivery date is, for example, 2 days for the shipping LT, 5 days for the logistics LT, and 4 days for the delivery date. The quantity of minutes. This is the case where the order and the order are on the same day, and if they are different, it may be necessary for the number of days.

  Further, as described above, the so-called product life cycle from the start of sales of products to the end of sales is generally considered to go through the stages of introduction, growth, maturity, and decline. During the decline period, the amount of demand decreases and the product life ends, so-called EOL (End Of Life).

  For this reason, as described above, if each department has a certain safety stock, materials, particularly materials dedicated to the product and unsold products may remain as surplus stock during EOL. In many cases, the dedicated materials and the excess product inventory are discarded and result in disposal loss. In particular, the surplus inventory of the dedicated materials and products often increases more than the actual demand if a certain safety stock is set in the case of a product with less customer demand.

  In addition, during the decline of the product life cycle, the number of products issued from the sales department (base warehouse) generally decreases, and the sales department also reduces the product inventory, and the product to the production department. We will also reduce orders. However, the material procurement department often has a large amount of material safety stock as a response to a sudden increase in product orders. Furthermore, for materials with long delivery lead times, orders may be placed as usual with information before the demand declines. Long-delivery parts often have high unit prices, such as electronic parts, and waste loss may increase.

  Furthermore, depending on the material order contract (purchase contract) with the supplier, it is necessary to purchase materials stocked by the supplier, which may lead to waste loss.

  As described above, the change of the safety stock is slow when it is performed at the time of demand fluctuation, and as described above, the surplus stock increases and the disposal loss may increase.

  In Patent Documents 1 to 3, the safety stock of the dedicated material at each stage of the life cycle is not taken into consideration, and it is difficult to reduce the disposal loss of the dedicated material at the time of the EOL.

  The present invention has been made in view of the above situation, and prevents delays in production due to a shortage of materials and shipment delays due to a shortage of product inventory even if a sales plan fluctuation with a sudden increase in sales exceeding the initially assumed fluctuation in sales occurs. An object of the present invention is to provide a supply chain efficiency support method capable of minimizing the loss of disposal of dedicated materials at the end of the product life.

The above object is achieved by the following method.
1. The sales plan for product sales and the demand plan for product procurement shift from future sales and demand forecast information (forecast information) to sales and demand confirmation information, and the sales and demand fluctuate. Including the sales plan and the demand plan, and the production in progress is scheduled to be terminated. A supply chain efficiency support method comprising a plurality of operations leading to a customer, the step of setting a supply chain model modeling the supply chain on a computer, and the conventional method at the beginning of a unit period in the supply chain For each sales plan and demand plan for the product and the successor product, Establishing a variable production plan based on the variable demand plan and storing it as storage information in a storage means; assuming an expansion variation in which the variation of the conventional product is increased; an expansion variation sales plan and an expansion variation demand plan; The step of planning the expansion variable production plan based on the expansion variable demand plan and inputting it into the storage means as the expansion variable information, the material inventory information on the material supply side, and the procurement contract information between the material supply side and the material procurement side Based on the steps to set supplier information, product information, production information, distribution route information, material information, material procurement condition information from ERP (Enterprise Resource Planning) package, each information of product, production, distribution route, Taking the fluctuation information and the enlarged fluctuation information from the storage means, based on these information The simulation data creating means creates simulation data and stores the simulation data in the storage means, and the supply chain model performs a simulation corresponding to the fluctuation based on the simulation data, and when the fluctuation occurs. Calculating a safety stock number of materials that minimizes the inventory cost of the material without causing a shortage of the conventional product and the successor product in total, and the remaining of the conventional product starting from the beginning The step of formulating demand forecast data in the life cycle, and in the supply chain model, based on the supplier information, the simulation data, the demand forecast data, the material information of the ERP package, and the material procurement condition information, A system that responds to fluctuations The total cost of the conventional product and the successor product does not occur when the expansion fluctuation occurs, and the disposal cost of the conventional product and its dedicated materials is minimized at the end of production of the conventional product. And a step of calculating a distribution route of the conventional product, the successor product and the material, and a series of processing in the step is performed in a cycle for each predetermined unit period. Supply chain efficiency support method.
2. 2. The supply chain efficiency support method according to 1, wherein the change in sales, demand, and production of the successor product includes a change in sales and production start time.
3. 3. The supply chain efficiency support method according to 1 or 2, wherein the plurality of operations include a material procurement operation, a production operation, a sales operation, and a sales base operation.
4). The material information includes information on whether the material is a dedicated material of the conventional product or a common material with other products including a successor product, and the information on the material procurement conditions includes the number of lots ordered and the material unit price. 4) Supply chain efficiency support according to any one of 1 to 3, characterized in that includes: data delivery lead time, data on fluctuations in material unit price with respect to fluctuations in the number of orders, and data on fluctuations in material delivery lead time. Method.
5). 5. The supply chain efficiency support method according to any one of claims 1 to 4, wherein the product information includes material used for the product, the quantity of the material, a process chart of the product, and data of the configuration.
6). The production information includes production plan information of product production volume and delivery date, stock information of materials, ordering information, delivery date information and price information, and product inventory information in production and sales. The supply chain efficiency support method according to claim 1.
7). 7. The supply chain efficiency support method according to any one of 1 to 6, wherein the distribution route information includes distribution lead time and distribution cost of distribution routes of products and materials.
8). In the simulation, the supply chain base information stored in the storage means, information related to the communication environment status, communication environment information, and distribution information related to the distribution status are extracted and added to perform the simulation. 8. The supply chain efficiency support method according to any one of 1 to 7.

  According to the above, the simulation is performed at a predetermined cycle, information on demand at each point in the product life cycle, stock of dedicated materials including stocks of products and suppliers, and material unit price based on the number of lots ordered for dedicated materials Based on the material delivery lead time and logistics route, by optimizing the material procurement conditions for dedicated materials, the number of dedicated materials in stock will not cause product shortages even if sales fluctuations exceed expectations, And can be minimized. Thereby, it is possible to reduce the disposal loss of the product and the dedicated material when the life cycle of the product ends.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited thereto.

  FIG. 7 is a table showing an example of changes in order forecast information (hereinafter also referred to as forecast) and order confirmation information (hereinafter also referred to as order confirmation). FIG. 7 shows an example in which the order interval, the forecast transmission interval, and the delivery lead time are set to one week. These intervals are appropriately set depending on the types of products and materials, and are, for example, two weeks or one month. The intervals may be different. In FIG. 7, the order confirmation is denoted as PO and the forecast as FC.

  In accordance with the ordering plan prepared by the first order, PO1 for order confirmation is ordered in one week of the planned ordering, and a forward FC1 is transmitted. PO1 is delivered in 2 weeks. In 2 weeks, FC1 is changed to PO2 and an order is placed, and a forecast FC2 is transmitted. PO2 is delivered in 3 weeks. The same goes for the following. FIG. 7 shows an example in which delivery is completed in nine weeks.

  In the example of FIG. 7, the ordering is performed by creating a material requirement plan by MRP (Material Requirements Planning) or the like based on the production plan every week.

  Further, order information such as reservation information (reservation) may be provided between forecast and order confirmation. In this case, as an example, Forecast is not a commitment to purchase materials, and reservation is a commitment to purchase, but is not a commitment, and order confirmation may be a commitment to both purchase and timing.

  Figures 2, 3, 4 and 5 show material ordering to production, including demand and production plans where product ordering information shifts from forecast to order confirmation and demand and production fluctuations may occur due to sales plan fluctuations. It is a flowchart which shows one Embodiment of the efficiency improvement support method of the supply chain which aims at the efficiency improvement of the supply chain of the product which reaches a customer (product shipping destination) through a process. Although the flowchart is divided into FIGS. 2, 3, 4 and 5 for the purpose of illustration, FIGS. 2, 3, 4 and 5 are integrated. For the supply chain 20, refer to FIG.

  In FIG. 4, the database 1 is a storage means for storing the various data and information described above, and the data and information of the ERP package 2 are also necessary via the relay program 6 and the data converter 7 which is a simulation data creation means. In response. In addition, simulation data created by the data converter 7 described later is also captured. Of the data and information of the ERP package 2, data and information that are not used by the data conversion unit 7 may be directly taken into the database 1 via the relay program 6 without using the data conversion unit 7.

  The ERP package 2 is an integrated business package, has an integrated database, and stores product information, production information, distribution route information, material information, material procurement condition information, and the like. The product information is based on the materials used for the product, the quantity of the material, the process schedule and data of the product, etc., and the production information is the product production volume, production lead time, delivery date, material delivery route, delivery lead time, inventory. , Ordering, delivery date, price information, product inventory information, etc. The distribution route information includes distribution lead time and distribution cost for each material in the normal distribution route and the temporary distribution route used for material procurement. The material information includes information on whether the material is a dedicated material of the product or a common material with other products including a successor product, and the material procurement condition information includes the order lot number and the order lot number of the material. Includes data on material unit price fluctuations and material delivery lead time fluctuations.

  The sales plan creation unit 3 creates a sales plan based on the actual demand (order) of the customer 21 at the beginning of the unit period in the supply chain 20. The sales plan is created for the EOL product and the successor product after the sale of the successor product is started.

  The sales plan creation unit 3 is provided in, for example, a management department in the sales base 22. The sales plan is transmitted to the demand plan creation unit 41. The unit period is a predetermined period in which a product production / sales plan is created, and production / sales are carried out by continuing the unit period. For example, it is set as appropriate according to the type, form, etc. of the product, such as every month, every three months, etc. The unit period is not always a fixed length. For example, the unit period may be changed at each stage of the product life cycle, introduction period, growth period, maturity period, decline period, and the like. Alternatively, the actual demand may vary every time.

  The demand plan creation unit 41 creates a demand plan based on the sales plan, the product inventory information of the base warehouse 42, and the entry / exit information, and taking into account sales fluctuations. Further, it is determined in which stage of the product life cycle the EOL product is assumed in advance, and EOL stage information is created. The demand plan includes forecast information and confirmation information for EOL products, and production request plan information for successor products.

  The base warehouse 42 temporarily stores the product delivered from the production department 24 and ships the product in response to a shipping request (order received) from the sales base 22. Information on the base warehouse 42 includes product inventory information, receipt / shipment information, and the like. The demand plan creation unit 41 and the base warehouse 42 are provided in the sales department 23, for example, the procurement management department.

  The demand plan and EOL stage information are transmitted to the production plan creation unit 5.

  Based on the demand plan, the production plan creation unit 5 creates production plans for EOL products and successor products in consideration of each condition of material procurement, factories, and logistics, and product inventory status in the production department 24. Restrictions on material procurement include parts production capacity and material delivery lead time. The factory constraint conditions include production lead time, process maximum production capacity, process production capacity switching condition, and the like. Distribution restrictions include product shipment and distribution lead time, distribution capability, warehouse inventory capability, and the like. The production plan creation unit 5 is provided, for example, in the production management department in the production department 24.

  The supplier information creation unit 43 creates supplier information based on information on stock of materials at each supplier that supplies materials and information on procurement contracts with each supplier. The procurement contract is an agreement on conditions for ordering and supplying materials between the supplier side and the procurement side. For example, when the production of the EOL product is terminated, it is contracted that the procurement side purchases the dedicated material for the EOL product that is surplus on the supplier side.

  The procurement contract is not limited to a collective contract for each supplier but may be a contract for each material. For example, the raw material level is not the target of the contract, but the component level is the target. The supplier information creation unit 43 is provided in the production department 24 or the material procurement department 25.

  The sales plan, demand plan, EOL stage information, base warehouse, production plan, and supplier information are input to the database 1 and the ERP package 2 via the relay program 6 and the data converter 7. These plans and information are applied to the supply chain 20 of the target product at the beginning of the unit period.

  With respect to the demand plan, the demand plan creation unit 41 assumes fluctuations in sales, and fluctuation information in virtual sales is set. As the fluctuation in the sales, an assumed sales fluctuation and an expanded sales fluctuation that increases the sales fluctuation are set.

  The sales fluctuations are for EOL products and successor products, referring to changes in customer orders at the sales base 22, sales fluctuations of similar products in the past, etc. It is set as appropriate in consideration of the total sales volume.

  Increased sales fluctuations are targeted for EOL products, referring to the expected delay in the start of production of the successor products, the maximum production capacity that can be produced by the production department 24, and the like. It is set as appropriate in consideration.

  Next, similarly, the demand plan creation unit 41 creates a fluctuation demand plan and an expanded fluctuation demand plan based on the sales fluctuation information, the product inventory information of the base warehouse 42, and the loading / unloading information.

  The variable demand plan and the expanded variable demand plan are transmitted to the production plan creation unit 5. The production plan creation unit 5 creates a fluctuation production plan and an expansion fluctuation production plan based on the sales fluctuation, the expansion fluctuation demand plan, and the constraint conditions.

  Each variation and each plan is input to the database 1 and the ERP package 2 through the relay program 6 and the data conversion unit 7.

  The data converter 7 creates simulation data based on the product information and production information, sales, demand, production plans, and supplier information stored in the ERP package 2.

  The data conversion unit 7 is provided, and the data conversion unit 7 is connected to the ERP package 2, the sales plan creation unit 3, the demand plan creation unit 41, the base warehouse 42, the production plan creation unit 5 and the supplier information creation unit 43, thereby providing the latest Simulation data can be created using this information. For example, even when the design change occurs and the data of the ERP package 2 is corrected, the data conversion unit 7 can always create simulation data based on the latest data of the ERP package 2. For this reason, simulation close to an actual system and with high accuracy becomes possible. Also, by creating simulation data in advance, it is possible to reduce the load for creating simulation data when performing a simulation, which will be described later, and to perform a quick simulation.

  The model creation unit 8 sets a supply chain model on a computer based on the simulation data based on information such as a supply chain configuration stored in the database 1. The supply chain model simulates an actual supply chain on a computer as a virtual supply chain. The actual flow of goods in the supply chain, each operation, etc. can be simulated on a computer.

  The supply chain model set by the model creation unit 8 is a model that performs simulation based on the sales fluctuation, and the material procurement is a normal procurement condition, that is, when the production plan has no fluctuation and the production is constant. The procurement conditions set in advance are applied. In the normal procurement conditions, the number of material ordering lots, the material unit price for the ordering lot number, and the material delivery lead time are set in advance.

  Here, the number of lots refers to the quantity of one lot.

  In addition, supply of products and materials is usually set by a distribution route. Hereinafter, the supply chain model is also referred to as model 1.

  Here, there are various logistics routes such as sea mail, automobile mail, air mail, etc. Generally, the logistics route has a long logistics lead time, for example, shipping costs are low, and the logistics lead time is short, for example, air mail. And so on. For this reason, usually, a logistics lead time is long as a logistics route but a logistics cost is low. For example, a shipping service is often used as a regular logistics route. On the other hand, in the present embodiment, the distribution route (air mail or the like) that is temporarily used although the distribution lead time is short but the distribution cost is high is referred to as a temporary distribution route.

  In the simulation condition setting unit 9, the simulation period, for example, to which period the sales fluctuation is set, or to which unit period after the first unit period, the initial inventory setting, the sales amount of the unit period, etc. Set the parameters such as the setting of the simulation conditions such as the setting of.

  Based on the simulation data and the simulation conditions, the simulation unit 10 uses the model 1 in the simulator and performs simulation for the EOL product and the successor product.

  According to the simulation, the number of safety stocks at the time of sales fluctuation (variable safety stock) is calculated so that the cost of material stock in the production department 24 is minimized and no shortage occurs at the time of sales fluctuation.

  Here, the number of safety stocks (variable safety stock) can be converted into safety stock days (variable safety stock days) based on the daily production amount at the time of change.

  The result evaluation unit 11 evaluates and examines the result of the simulation (the number of variable safety stocks), and when it is necessary to change the conditions and perform simulation, the simulation condition setting unit 9 sets the conditions again and performs the simulation. Can do. Thereby, the range of evaluation can be expanded.

  The simulation result information is fed back as a variable safety stock setting value or a variable safety stock days setting value, stored in the database 1, and further transferred to the ERP package 2 for storage. The simulation result transferred to the ERP package 2 is taken into the supply chain 20 and reflected in actual product inventory planning, material requirement planning, order confirmation, and forecasting.

  Next, based on the information such as the supply chain configuration stored in the database 1 by the model creation unit 12, a supply chain model for performing a simulation based on the expanded sales fluctuation is set on the computer based on the simulation data. The supply chain model set by the model creation unit 12 is referred to as model 2.

  The model 1 and the model 2 are named differently for the sake of explanation, but the structure of the supply chain is the same.

  In model 2, material information, material procurement condition information, and supplier information are added to model 1 described above. Information on whether the material information is a dedicated part of the product for each material or a common part with another product including a successor product, and if it is the common part, the model of the other product that uses the common part Contains data on the number used. The material procurement condition information includes data on the number of ordered lots of the material, fluctuations in the material unit price with respect to fluctuations in the number of ordered lots, and fluctuations in material delivery lead time with respect to fluctuations in the number of ordered lots. The supplier information includes information on inventory of materials at each supplier 26 that supplies materials, information on procurement contracts with each supplier, and information on materials that the procurement side (material procurement department 25) compensates for purchases based on the procurement contracts. Contains information.

  Here, at the time of EOL of the product, if the material is a common material with other products, it is possible to prevent the excess inventory from being discarded by diverting it to other products. Except for diversion, it is discarded, resulting in disposal loss. Therefore, the disposal loss is mainly affected by the surplus inventory of dedicated materials. The disposal loss of the dedicated material occurs not only in the production department and the material procurement department in the factory, but also in the stock of the material of the supplier 26 for which the material procurement department 25 compensates the purchase by the contract.

  The model 2 has a function of reducing the waste loss at the time of product EOL. Here, the disposal loss means the total cost (amount of disposal) of the dedicated material to be discarded. The dedicated material disposal loss reduction function can cope with the anticipated expansion and sales fluctuations, and the number of dedicated materials in stock and material procurement to minimize the disposal loss of dedicated materials in the production department 24 at the time of product EOL Calculate the conditions.

  In addition, the model 2 has a temporary distribution route (air mail, etc.) added to the distribution route for products and materials in addition to the model 1 described above, and the product is supplied through the normal distribution route (shipping service, etc.) and the temporary distribution route. And material logistics lead time and costs, as well as base warehouse information. The model 2 also has a function for calculating the logistics cost and product and material inventory, a material for the production department 24, a product safety stock, and a product safety stock for the base warehouse 42.

  Further, referring to the above-mentioned EOL stage information, demand forecast data in the remaining life cycle of the EOL product from the beginning of the unit period to the EOL is formulated. For the demand forecast data, an application program (demand forecasting tool) that realizes a known demand forecasting method that has been generally proposed is selected according to product characteristics, added to model 2, and used on a computer. It is formulated.

  In the simulation condition setting unit 13, the simulation period, for example, to which period the expanded sales fluctuation setting is set, or to which unit period after the first unit period, the initial safety stock quantity setting, the unit period Set the parameters such as the production volume and set the simulation conditions.

  In the simulation unit 14, simulation is performed using the model 2 based on the simulation data, the simulation condition and demand prediction data, the material information, the material procurement condition information, and the supplier information.

  Generally, the material unit price increases as the order lot number decreases. In addition, if the number of order lots decreases, the material supplier assumes a decrease in the subsequent material order, and often reduces or stops the preparation in the prospective production, and the delivery lead time may fluctuate.

  In addition, as described above, in ordering materials, materials with long delivery lead times may be ordered with the same number of order lots as before with information before demand decreases. In this case, especially in the case of dedicated parts with a long lead time for delivery, it was not possible to cope with a decrease in demand, resulting in an increase in disposal loss.

  For this reason, referring to demand forecast data, place orders by changing the material procurement conditions at the time when demand decline is predicted, that is, placing orders that can reflect demand information more by reducing the number of lots ordered. Can be considered. However, in this case, the material unit price increases.

  For this reason, in order to minimize the disposal loss of the dedicated material in the production department 24 at the time of EOL, it is necessary to mutually optimize the material procurement conditions, that is, the order lot number, the material unit price, and the delivery lead time. .

  In the simulation, based on the expanded sales fluctuations in the unit period and the demand forecast data in the remaining life cycle, the number of dedicated materials in stock and the material procurement conditions that minimize the material disposal loss in the production department 24 during EOL are calculated. The Further, the minimum safety stock number and the temporary distribution route that minimize the product stock in the base warehouse 42 and the material stock in the production department 24 are also calculated.

  Here, in the case of common materials, in order to suppress an increase in material unit price, the procurement conditions such as the number of inventory and the distribution route may not be changed in consideration of the amount of surplus materials at EOL that can be diverted to other products.

  The result evaluation unit 15 evaluates and examines the result of the simulation (the number of products and dedicated materials in stock, material procurement conditions, temporary logistics route), and if it is necessary to change the conditions for simulation, the simulation condition setting unit again 13 can set a condition and perform a simulation. Thereby, the range of evaluation can be expanded.

  The information of the simulation result includes the minimum safety stock number and temporary distribution route of the product of the base warehouse 42 corresponding to the expanded sales fluctuation, the material procurement condition of the dedicated material of the production department 24, and the safety stock number and procurement of the material including the dedicated material. The temporary logistics route is fed back, stored in the database 1, and further transferred to the ERP package 2 for storage. Furthermore, it is reflected in the supply chain 20. Reflection to the supply chain 20 may be part or all, and may be set as appropriate. For example, depending on the material, the price may be low, and the amount may be small even if it is pre-stocked or discarded at the time of EOL. In addition, the temporary distribution route is applied to the supply chain 20 when an expansion production fluctuation occurs.

  In the simulation of the above-described models 1 and 2, the simulation is performed by extracting from the database 1 the information on the bases constituting the supply chain, the information on the communication environment, the communication environment information, and the distribution information on the distribution state. It is preferable to carry out. As a result, a simulation that is closer to the actual system and highly accurate is possible.

  Furthermore, a sales plan is created according to the actual demand (order) of the customer 21 of the supply chain 20 described above, sales fluctuations and expanded sales fluctuations are assumed, and simulations are performed based on demand forecasts in the product life cycle. A series of optimization processes for optimizing the chain 20 is performed at predetermined intervals and reflected in the supply chain 20. The predetermined cycle is the stage of introduction, growth, maturity, and decline in the life cycle of the above-mentioned product every time the actual demand fluctuation (actual sales fluctuation) of the customer 21 occurs in the supply chain 20 every certain period. Or a combination of these. The predetermined period is preferably set as appropriate in consideration of the market position, demand, characteristics, product life, etc. of the product. Moreover, it is preferable to shorten the said predetermined period in the decline period of a product, ie, near EOL.

  In this way, the above simulation is performed at a predetermined cycle, information on demand at each point in the life cycle of the product, inventory of dedicated materials including inventory at products and suppliers, material unit price by the number of lots ordered for dedicated materials, materials By optimizing the procurement conditions for dedicated materials based on the delivery lead time and logistics route, the number of dedicated materials in stock can be minimized without causing product shortages even if sales fluctuations exceed expectations. It can be. Thereby, it is possible to reduce the disposal loss of the product and the dedicated material when the life cycle of the product ends.

  Also, based on the results of the above simulations, it is predicted not only when the demand fluctuation has been reduced, but also when the production has increased, how many times the demand fluctuation in the current material inventory can be produced without delay in delivery. In addition, it is possible to provide a highly accurate delivery date response to the sales department.

  FIG. 6 shows an example of a flow chart for improving the efficiency of the supply chain using the supply chain efficiency support method shown in FIGS. It is assumed that necessary data and information are captured from the ERP package 2 in the database 1.

  In step S101, a sales plan, a demand plan, and a production plan for an EOL product and a successor product corresponding to the actual demand of the customer 21 in the supply chain 20 are created.

  In step S102, the demand plan creation unit 41 assumes and sets sales fluctuations of the EOL product and the successor product.

  In step S103, a variable demand plan and a variable production plan are created based on the sales fluctuation.

  In step S104, the data conversion unit 7 creates simulation data based on the product information, production information, sales, demand, production plans, and supplier information of the ERP package 2.

  In step S105, the model creation unit 8 creates a supply chain model (model 1) that models the supply chain on the computer based on information such as the supply chain configuration stored in the database 1.

  In step S106, the simulation condition setting unit 9 sets the simulation conditions by the person in charge. The simulation conditions are set for a simulation period, an opening inventory, a parameter setting such as a sales amount for a unit period, and the like.

  In step S107, the simulation unit 10 performs a simulation using the model 1 based on the simulation data and the simulation conditions. As a result of the simulation, the material fluctuation cost is minimized at the time of sales fluctuation, and the sales fluctuation does not occur. The number of safety stocks at the time (variable safety stock number) is calculated.

  In step S108, the result evaluation unit 11 evaluates the simulation result (the number of variable safety stocks). Further, if it is necessary to change the conditions for simulation (step S108; No), the conditions are set again in step S106 and the simulation is performed. If re-simulation is not required (step S108; Yes), the simulation result is stored in the database 1 in step S109.

  In step S110, the simulation result (variable safety stock number) is transferred from the database 1 to the ERP package 2 and reflected in the data and information of the ERP package 2.

  In step S111, the result of the simulation (the number of variable safety stocks) is reflected in the supply chain 20.

  In step S112, the demand plan creation unit 41 assumes and sets an expanded sales fluctuation for the EOL product.

  In step S113, an expanded variation demand plan and an expanded variation production plan are created based on the expanded sales variation.

  In step S114, the model creation unit 12 creates a supply chain model (model 2) obtained by modeling the supply chain on the computer based on information such as the supply chain configuration stored in the database 1. In model 2, material information, material procurement condition information, and supplier information are added to model 1 described above. The model 2 has a function of reducing the waste loss at the time of product EOL. Further, with reference to the above-mentioned EOL stage information, demand forecast data in the remaining life cycle from the beginning of the unit period to EOL is formulated.

  In step S115, the simulation condition setting unit 13 sets the simulation conditions by the person in charge. The simulation conditions are set such as a simulation period, an initial safety stock quantity setting, a parameter setting such as a sales volume setting for a unit period, and the like.

  In step S116, simulation using the model 2 is performed in the simulation unit 14 based on the simulation data, the simulation conditions and demand prediction data, the material information, the material procurement condition information, and supplier information. Based on the above simulation, based on the expanded sales fluctuation of the unit period and the demand forecast data in the remaining life cycle, the minimum safety stock number and temporary distribution route of the product in the base warehouse 42 at the time of EOL, and the material procurement conditions for the dedicated material of the production department 24 And the safety stock number of materials including dedicated materials and the temporary logistics route of procurement are calculated.

  In step S117, the result evaluation unit 15 evaluates and examines the result of the simulation (the minimum safety stock number of the product, the stock number of the dedicated material, the material procurement condition, and the temporary logistics route). If it is necessary to change the conditions for further simulation (step S117; No), the conditions are set again in step S115 and the simulation is performed. If re-simulation is not required (step S117; Yes), the simulation result is stored in the database 1 in step S118.

  In step S119, the simulation result is transferred from the database 1 to the ERP package 2 and reflected in the data and information of the ERP package 2.

  In step S120, the simulation result is reflected in the supply chain 20.

It is the schematic which shows an example of a supply chain. It is a flowchart which shows an example of the efficiency improvement support method of the supply chain which concerns on this invention. It is a flowchart which shows an example of the efficiency improvement support method of the supply chain which concerns on this invention. It is a flowchart which shows an example of the efficiency improvement support method of the supply chain which concerns on this invention. It is a flowchart which shows an example of the efficiency improvement support method of the supply chain which concerns on this invention. An example of the flowchart which aims at the efficiency improvement of the supply chain which concerns on this invention is shown. It is a figure which shows transition of forecast information and material order confirmation information.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Database 2 ERP package 3 Sales plan creation part 41 Demand plan creation part 42 Base warehouse 43 Supplier information creation part 5 Production plan creation part 6 Relay program 7 Data conversion part 8, 12 Model creation part 9, 13 Simulation condition setting part 10, 14 Simulation Department 11, 15 Result Evaluation Department 20 Supply Chain 21 Customer 22 Sales Base 23 Sales Department 24 Production Department 25 Material Procurement Department 26 Supplier

Claims (8)

The sales plan for product sales and the demand plan for product procurement shift from future sales and demand forecast information (forecast information) to sales and demand confirmation information, and the sales and demand fluctuate. Including the sales plan and the demand plan, and the production in progress is scheduled to be terminated. A supply chain efficiency support method consisting of multiple operations leading to customers,
Setting a supply chain model that models the supply chain on a computer;
For the sales plan and demand plan of the conventional product and the successor product at the beginning of the unit period in the supply chain, a variable sales plan and a variable demand plan assuming fluctuations, and a variable production plan based on the variable demand plan Planning and storing as fluctuation information in the storage means,
Assuming the expansion fluctuation of the conventional product with the fluctuation increased, the expansion fluctuation sales plan and the expansion fluctuation demand plan and the expansion fluctuation production plan based on the expansion fluctuation demand plan are drawn up and input to the storage means as the expansion fluctuation information. Steps,
Setting supplier information based on material inventory information on the material supply side and procurement contract information between the material supply side and the material procurement side;
Product, production, and distribution route information from an ERP (Enterprise Resource Planning) package that stores product information, production information, distribution route information, material information, and material procurement condition information, and the variation information and the expanded variation from the storage means Information is taken, based on these information, the simulation data is created by the simulation data creation means, and stored in the storage means;
In the supply chain model, based on the simulation data, a simulator is used to perform the simulation corresponding to the fluctuation, and when the fluctuation occurs, the stock of the conventional product and the successor product does not occur, and the material Calculating the safety stock quantity of the material with the lowest inventory cost;
Formulating demand forecast data in the remaining life cycle of the conventional product starting from the beginning;
Based on the supplier information, the simulation data, the demand forecast data, the material information of the ERP package and the material procurement condition information, the simulator performs a simulation corresponding to the expansion variation, and the expansion variation occurs. The number of stocks in which the disposal cost of the conventional product and its dedicated materials is minimized at the end of production of the conventional product, Calculating a distribution route for successor products and materials,
A method for supporting efficiency in a supply chain, wherein a series of processing in the steps is performed in a cycle for each predetermined unit period. The supply chain efficiency support method according to claim 1, wherein the change in sales, demand, and production of the successor product includes a change in sales and production start time. 3. The supply chain efficiency support method according to claim 1, wherein the plurality of operations include a material procurement operation, a production operation, a sales operation, and a sales base operation. The material information includes information on whether the material is a dedicated material of the conventional product or a common material with other products including a successor product, and the information on the material procurement conditions includes the number of lots ordered and the material unit price. The supply chain efficiency according to any one of claims 1 to 3, further comprising: data of a material delivery lead time, a material unit price fluctuation with respect to a change in the number of orders, and a material delivery lead time fluctuation data. Support method. 5. The supply chain efficiency support according to claim 1, wherein the product information includes material used for the product, the quantity of the material, a process chart of the product, and data of the configuration. Method. 6. The production information includes production plan information of product production volume and delivery date, material inventory information, ordering information, delivery date information and price information, and product inventory information in production and sales. The supply chain efficiency support method according to any one of the above. 7. The supply chain efficiency support method according to claim 1, wherein the distribution route information includes distribution lead time and distribution cost of distribution routes of products and materials. In the simulation, the supply chain base information stored in the storage means, information related to the communication environment status, communication environment information, and distribution information related to the distribution status are extracted and added to perform the simulation. The supply chain efficiency support method according to any one of claims 1 to 7.

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