JP2011065224A - Supply chain efficiency improvement support method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a supply chain efficiency improvement support method capable of preventing the stockout of a product caused by the stockout of a material even if a change occurs in a sales plan of the product, and capable of minimizing of a disposal loss of the material or the like at production end. <P>SOLUTION: The supply chain efficient improvement support method includes steps of: performing simulation by a supply chain model of a factory unit about the products of a plurality of factories, deriving a physical distribution route and a safe stock amount where the disposal cost of the surplus stock of the material or the like at the production end becomes minimum in the factory unit without causing the stockout of the product; and performing simulation about a common material used in common between a plurality of products by the supply chain model where the supply chain models of the factory units are integrated, and deriving the physical distribution route and the safe stock amount where the disposal cost of the surplus stock of the common material at the production end becomes minimum on an entire inter-factory basis without causing the stockout of the product. A series of processing in the steps is performed at a period of each prescribed period. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention provides a supply chain that does not cause a product shortage even if a sales plan fluctuates in the product supply chain, and that can reduce a material disposal loss that occurs at the end of product production. It relates to an efficiency support method.

  By the time a product arrives at a customer, multiple operations from procurement of materials (hereinafter also referred to as parts) to delivery to the customer, for example, each operation such as material procurement, production, sales and logistics (hereinafter also referred to as departments) It exists and 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.

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

  When improving the efficiency of a supply chain where there are multiple operations, production information such as production volume and delivery date, procurement / production / distribution / sales, etc. and information on their bases should be considered 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 of creating a supply chain model on a computer and performing simulation on the computer to improve the efficiency of 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 for business activities such as procurement, production, sales, and logistics of materials, it is necessary to capture the flow of materials in real time for all operations in the supply chain. . 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, distribution, 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 drawn up based on orders from customers, sales forecasts, etc., and materials are procured from the material supply side (hereinafter referred to as suppliers) from outside or other factories, and production activities are carried out in the production process. Is done.

  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 includes a sales department in a sales department of a manufacturing company that produces products, and a sales company such as a distributor or an agent that is 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. Accordingly, the warehouse information is also base warehouse information including product inventory information of the base warehouse 42. 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 goods, and broken arrows indicate the flow of information such as orders.

  In the example shown in FIG. 1, the place where the production department 24 and the material procurement department 25 are provided is the factory 201, but the material procurement department 25 may be provided in a place different from the factory 201.

  Hereinafter, the stock of products and materials in the production department 24 and the material procurement department 25 is also referred to as stock in the factory 201 (factory stock).

  The supplier 26 orders and procures the raw material used for the received material from the raw material supplier, for example, a raw material supplier or a parts supplier.

  Hereinafter, the materials refer to parts and members procured by the material procurement department 25 such as parts and members for assembling the product main body and members (for example, accessories and packing materials) for bringing the product into a shipping state. .

  The raw material refers to a member procured for use by the supplier 26 for the ordered material. For example, a general commercially available part (for example, an electronic part) for completing an ordered part (for example, an electronic board) is also referred to as a raw material.

  In FIG. 1, the material supplier, the parts supplier, etc. that are ordered by the supplier 26 are omitted.

  When ordering the above products, in addition to the product order confirmation information, in general, in order to facilitate procurement, product procurement prospect information (assuming the number of future product orders from the procurement side (ordering side) to the supply side (supplier) ( Forecast information). 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 remain constant, and sales plans may vary. As a result, demand and production plan fluctuations may occur when changing from forecast information to confirmed information.

  In addition, the so-called product sales life cycle from the start of sales until the end of sales is considered to go through the stages of introduction, growth, maturity, and decline, for example. During the decline period, the amount of demand decreases, and the product life in the product life cycle ends, that is, sales end.

  Further, if the life cycle of the sales is applied from the start of production to the end of production at different times, it can be regarded as a rough production life cycle.

  Hereinafter, in the production life cycle as viewed from the production side, the time when production ends is also referred to as a so-called end of life (hereinafter also abbreviated as EOL).

  FIG. 8 is a schematic diagram illustrating an example of a product life cycle. The time when production ends, EOL indicates the decline period.

  Here, at the end of a product that has been sold and reaches the end of its life cycle, that is, the current product (hereinafter referred to as EOL product), in many cases, the production and sale of the next product that will succeed the EOL product The EOL product will be switched to the next product. However, since the next product is a new product, the production start time may fluctuate from the original plan due to sales strategy, production, quality, etc. (in many cases, it will be delayed). For this reason, sales and production fluctuations of the next product occur, and accordingly, sales and production of EOL products may also fluctuate. As described above, fluctuations in sales and production may occur at the time when the product is switched from the EOL product to the next product.

  In response to such fluctuations, it is possible to prevent delays in production due to shortage of materials, particularly materials (parts) with long delivery lead times, and delays in shipment due to shortage of products, and materials that can minimize inventory costs, and Product inventory is desired.

  Further, the stock and materials of the EOL product at the time of EOL may become surplus stock. Product inventory is often sold after the end of production, and can often be processed by so-called inventory disposal at the time of sale. However, the inventory of materials often remains as surplus inventory and is often discarded and causes disposal loss. . For this reason, reduction of this waste loss is desired.

  In contrast to the above, the error of the past forecast information, the average value of the error, and the standard deviation of the error are derived from the past forecast information and the order received corresponding thereto, and the current forecast information is corrected. From the above, it is disclosed that the order quantity is derived. (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).

JP 2006-39802 A JP 2007-226718 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, with the correction of the current forecast information and the calculation of the order quantity with reference to the past forecast information and the order results corresponding to this, the order quantity when the production of the product is going to end is also the material inventory quantity. This has had an impact on the waste loss.

  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, sales toward the end of production and response to demand fluctuations are not considered, and reduction of waste loss is not considered.

  As described above, the sales plan may change in demand and production plan when changing from forecast information to finalized information due to changes in orders from customers and changes due to product switching.

  In response to such fluctuations, it is possible to prevent delays in production due to shortage of materials, particularly materials (parts) with long delivery lead times, and delays in shipment due to shortage of products, and materials that can minimize inventory costs, and Product inventory is desired.

  In addition, as described above, the stock of materials at the time of EOL of EOL products, particularly the stock of dedicated materials for the corresponding products, remains as surplus stock and is often discarded, resulting in disposal loss. Is desired.

  Furthermore, depending on the material order contract (purchase contract) with the supplier, it is necessary to purchase materials and raw materials to be stocked at the supplier upon completion of the order, which may lead to disposal loss.

  Here, in general, a manufacturing company or the like that manufactures a product often has a plurality of factories and produces a plurality of products. In many cases, one of the plurality of factories produces a plurality of products. The plurality of products include those having different purposes / functions, those having the same purposes / functions, but having different destinations. In many cases, the plurality of products include products having different life cycle stages, such as products in which EOL results in disposal loss and products that are continuously produced.

  In addition, in order to reduce costs and improve production efficiency among these multiple products, many materials are being shared. Since such common materials are related between products and factories, the optimization of inventory for one product and one factory can reduce the optimal inventory and effective waste loss for the entire common material. It is difficult to plan.

  Furthermore, materials (parts in particular) are not only used for production of products, but also serve as repair parts (service parts) used for after-sales services such as repair and maintenance of products after the products are sold to the market. . Therefore, the procurement of materials and the safety stock must also take into account a supply parts plan for supplying parts as service parts.

  In Patent Documents 1 and 2, the safety stock of products and materials at each stage of the product life cycle is not considered, and it is difficult to reduce the waste loss of materials at the time of EOL. .

  The present invention has been made in view of the above situation, and can prevent a delay in production due to a material shortage and a shipment delay due to a shortage of product inventory even when the sales plan fluctuates in the life cycle of the product, and when the production ends. It is an object of the present invention to provide a supply chain efficiency support method capable of minimizing waste loss of materials, etc.

  The above object is achieved by the following method.

1. When the sales plan for sales of products that include common materials used in the materials to be used and produced at multiple factories and the demand plan for product procurement shift from future prospect information (forecast information) to final information A supply chain efficiency support method for improving the efficiency of the supply chain of the product consisting of a plurality of operations ranging from procurement of materials that may fluctuate through production processes to customers,
A step of integrating a supply chain model in which the supply chain is modeled in a factory unit, a supply chain model in the factory unit, and an integrated supply chain model on a computer;
Creating the sales plan at the beginning of a unit period of the product in the supply chain, the demand plan based on the sales plan, and producing a production plan based on the demand plan and storing it as storage information in each storage means;
Predicting the demand in the remaining period from the beginning of the product to the end of production in the life cycle of the product, and storing it in storage means as residual demand prediction information;
The supplier that supplies the material to the material procurement side, based on the number of the material and the raw material used for the material, information about the material and the product that is the target of the material, material production end information, and procurement contract information Creating information and storing it in a storage means;
Establishing supply parts plan information assuming the demand for service parts used for after-sales service of the product, and storing it in the storage means;
Based on product information, production information, distribution route information, material information, material procurement condition information, and sales, demand, and production plan information stored in an ERP (Enterprise Resource Planning) package, simulation data is created by simulation data creation means. Creating and storing in the storage means;
Based on the simulation data, the remaining demand forecast information, the supplier information, and the supply part plan information, the factory unit simulation is performed on the computer in the factory unit supply chain model. Deriving the selection of the material, the safety stock number of the raw material and the distribution route that minimize the total disposal cost of the material and the surplus stock of the raw material at the factory and supplier at the end of production without causing shortage; and ,
In the integrated supply chain model, based on the information derived in the factory unit simulation, the remaining demand forecast information, the supplier information, and the supply parts plan information for common materials used in common among the products, The number of safety stocks and the number of transfers between factories that minimize the waste disposal cost of the common stock at the factory and suppliers at the end of production without causing a shortage of the product by performing simulation on the computer A method for deriving a distribution route between factories, and a series of processing in the step is performed at a cycle every predetermined period.

  2. 2. The supply chain efficiency support method according to 1 above, wherein the plurality of operations include material procurement operations, production operations, sales operations, sales base operations, and logistics operations related to the respective operations.

  3. 3. The supply chain efficiency support method according to 1 or 2, wherein the sales plan, the demand plan, and the production plan each include a plan for each destination.

  4). 4. The supply chain efficiency support method according to any one of claims 1 to 3, wherein the remaining demand prediction information includes a schedule until the end of production for each destination of the product.

  5. The supplier information includes the number of stocks of the material in the supplier, the number of stocks and order lots of raw materials used for the material, the raw material common information indicating whether the raw material is dedicated to the product or common with other products, the raw material production end 5. The supply chain efficiency support method according to any one of items 1 to 4, further comprising information and procurement contract information.

  6). The material information includes information on whether the material is a dedicated material for the product or a common material with other products including the next product, and the material procurement condition information includes the number of lots ordered, the material unit price, 6. The supply chain efficiency support method according to any one of 1 to 5 above, including data on 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. .

  7. 7. The supply chain efficiency according to any one of 1 to 6 above, wherein the product information includes data to be used, quantity of the material, process chart, and configuration data for each destination of the product. Support method.

  8). The production information includes the production amount information of the product and the production plan information of the delivery date, the change of the production amount and the delivery date of the product when the next product is put on the market, the information of the production plan, the stock information of the material, the order information and the delivery date information. The supply chain efficiency support method according to any one of 1 to 7, characterized in that: product price information, product inventory information in production and sales is included.

  9. 9. The supply chain efficiency support method according to any one of 1 to 8, wherein the distribution route information includes a distribution lead time and a distribution cost of a distribution route of products and materials.

  10. 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. 10. The supply chain efficiency support method according to any one of 1 to 9 above.

  As described above, it is possible to optimize the safety stock number of the dedicated material limited to each product or each factory without causing a shortage, and to reduce the disposal loss of the dedicated material at the time of the product EOL. Furthermore, it is possible to optimize the safety stock number of common materials and the inventory location including the movement of common materials to reduce the loss of disposal of common materials.

It is the schematic which shows an example of a supply chain. It is a block diagram which shows an example of the efficiency improvement support method of the supply chain which concerns on this invention. It is a block diagram which shows an example of the efficiency improvement support method of the supply chain which concerns on this invention. It is a block diagram which shows an example of the efficiency improvement support method of the supply chain which concerns on this invention. It is a block diagram 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. It is the schematic which shows progress of the life cycle of a product.

  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.

  2, 3, 4 and 5 are block diagrams showing an embodiment of a supply chain efficiency support method for improving the efficiency of the supply chain according to the present invention. Although the block diagram is divided into FIGS. 2, 3, 4 and 5 for the purpose of illustration, FIGS. 2, 3, 4 and 5 are integrated.

  Here, the product according to the present invention refers to a plurality of products produced in a plurality of factories, including materials used in common among products (common materials). Accordingly, products that do not use common materials even if they are produced in the same factory are excluded.

  Some manufacturing companies have factories in many regions and many types of products. In such a case, if all factories and products are targeted, the target range may be wide and very complicated. In such a case, the target factory may be limited to a plurality of settings, for example, limited to a specific region, and products manufactured using materials including common materials may be targeted. . In addition, when there are many types of products, the target product may be set in advance based on the size of the ratio of the common material to the material of the product. In addition, if the target common material is not all of the common material and a disposal loss occurs, the common material may be set as a target so as to have a certain amount of money or more. Furthermore, these may be combined.

  The supply chain 20 refers to FIG. The supply chain 20 has a plurality of operations including a material procurement operation, a production operation, a sales operation, a sales base operation, and a logistics operation related to each operation.

  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 information on a target product, that is, a plurality of products produced in a plurality of factories that include materials common to the materials used.

  Here, the plurality of products include those having different purposes / functions as described above and those having the same purposes / functions but different destinations. In the plurality of products, products having different life cycle stages, such as products that become EOL and cause a loss of loss, and products that continue to be produced are mixed.

  In addition, the same product may be distributed to a plurality of factories. In this case, even for the same product, production is terminated in one factory and production is continued in another factory.

  The product information includes materials to be used for each destination of each product, the quantity of the materials, product process charts, configuration data, and the like.

  The production information includes production plans and delivery schedules for each product, production lead time, material delivery route, delivery lead time, inventory, ordering, delivery date, price information, product inventory information, and the like. The production plan information (production plan information) includes production plan information on the production amount and delivery date of a product created in response to the delay when the next product is put on the market.

  The distribution route information includes a distribution lead time and a distribution cost for each material in a distribution route normally used in material procurement (normal distribution route) and a temporary distribution route (temporary distribution route). 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.

  The material information is information on whether it is a dedicated material for each product (each factory) or a common material between products including the next product (between factories) for each material, and if it is the common part, the common part Includes data on the model and number of products used.

  The material procurement condition information includes data on the order lot number of the material, fluctuations in the material unit price with respect to fluctuations in the order lot number, and fluctuations in the material delivery lead time.

  The sales plan creation unit 3 creates a sales plan for each product 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 after the start of sales of the next product when it is decided to sell the product (EOL product) and the next product.

  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 above-mentioned 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 in 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 for each product based on the sales plan, the product inventory information of the base warehouse 42, the entry / exit information, and the estimated amount of fluctuation estimated from the fluctuation of the sales plan. The estimation of the change in the sales plan is to estimate how much the quantity change may occur in the sales plan. For example, it is estimated that a maximum of 1.5 times fluctuation occurs in the quantity of the sales plan. This estimation is made with reference to past performance of similar models, trends in the next product, market trends, and the like.

  Further, it is determined in which stage of the life cycle of the product the EOL product is assumed in advance, and EOL stage information is created. The demand plan includes forecast information and confirmation information of EOL products and production request plan information of the next product.

  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. The information of the base warehouse 42 (base warehouse information) includes product inventory information and receipt / shipment information. 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 a production plan for the EOL product in consideration of each constraint condition of material procurement, factory, and distribution and the product inventory status in the production department 24. In addition, a production plan for the next product will be created as necessary. The production plan includes a destination production plan for each destination based on the setting of the quantity for each destination in the demand plan.

  Restrictions on material procurement include parts production capacity and material delivery lead time. Factory constraints include production lead time, process maximum production capacity, process capacity switching conditions, 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 including stock information of materials at each supplier 26, the number of raw materials in stock and the number of order lots, raw material common information, raw material production end information, and procurement contract information.

  The number of lots ordered for raw materials is the number of lots ordered for raw materials used for materials, that is, the number of lots ordered for raw materials at the supplier 26. The raw material common information is information on whether the raw material in the supplier 26 is dedicated for each product or common among products, and the raw material production end information is information that exists only when the end of production of raw materials is scheduled. It is. The procurement contract information is a contract for conditions for ordering and supplying materials between the supplier side and the procurement side. For example, when the production of a certain product is terminated, it is contracted that the procurement side purchases the exclusive materials and raw materials of a certain product surplus on the supplier side.

  Procurement contracts are not limited to contracts for each supplier, but may be contracts for each material. For example, the raw material level is not covered by the contract, but the part level is covered. The supplier information creation unit 43 is often provided in the production department 24 or the material procurement department 25, for example.

  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.

  The supply part plan creation unit 44 creates a supply part plan for service parts used for after-sales service of products. The supply part plan creation unit 44 is provided, for example, in a parts center of an after-service department that manages the overall after-sales service of products already sold. The parts center procures service parts and supplies them to the market. The replenishment of the service parts is performed for a predetermined period even after the production and sales of the product are completed. For this reason, the procurement of service parts is based on the quantity already sold and the quantity planned to be sold in the future. It is carried out while shifting from forecast to confirmed information every time. Further, in order to procure service parts, an order from the parts center to the material procurement department 25 is often used.

  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.

  Based on the sales / demand / production plan information, the product information stored in the ERP package 2, the production information, the distribution route information, the material information, and the material procurement condition information in the data conversion unit 7 which is a simulation data creation means Simulation data is created.

  The simulation data is a data table obtained by converting each information data into numerical values and symbols so that the data can be used on a computer. For example, a sales plan, a demand plan, and a production plan are coded and linked to data related to each plan to create a data table.

  Also, in order to make it easy to use the supplier information on the computer in the data conversion unit 7, the name, the number of stocks, the number of lots ordered, whether or not the products are common for each material and raw material at each supplier 26, and the procurement contract. It is also possible to create a data table by symbolizing and digitizing the presence / absence of the purchase guarantee of surplus items.

  Furthermore, in order to make it easy to use the spare parts plan information on a computer, it is symbolized and digitized every time a time and quantity of procurement forecast and finalized information for each service part is set, and a data table is created. Is preferred.

  A data conversion unit 7 is provided. The data conversion unit 7 is an ERP package 2, a sales plan creation unit 3, a demand plan creation unit 41, a base warehouse 42, a production plan creation unit 5, a supplier information creation unit 43, and a supply part plan creation unit. By linking with 44, simulation data and a data table can be created using the latest 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 (SC model) on a computer with reference to 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 configuration is stored in the database 1 for each product. When setting a supply chain model, when there are a plurality of target products in one factory, a supply chain model including the target products is set by combining the configurations of these supply chains. When there is one target product in one factory, a supply chain model is set based on this supply chain configuration. Therefore, it becomes a supply chain model of a factory unit limited to the target product.

  Thus, the supply chain model set by the model creation unit 8 is a model (factory SC model) that performs simulation (factory simulation) in units of factories. The example of FIG. 4 is a case where there are two target factories, and two of the first factory SC model and the second factory SC model are set.

  In the factory SC model, initially, material procurement refers to normal procurement conditions, that is, preset procurement conditions that are applied when the production plan does not change and production is constant. 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.

  The factory SC model is a function for calculating distribution costs and inventory costs of products, materials and raw materials, materials at the factory 201, safety stock of products, safety stock of products at the sales side, and safety stock of materials and raw materials at the supplier 26. And a function of reducing these disposal losses during product EOL.

  Here, the disposal loss means a total cost (amount of disposal) of products, materials, and raw materials to be discarded.

  At the time of EOL of the product, if the material is a common material with other products including the next product, excess inventory can be reduced by diverting it to other products. Except for diversion, it is discarded, resulting in disposal loss.

  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.

  In addition, raw materials that are stocked at the supplier 26 and compensated for purchase by the material procurement department 25, mainly dedicated raw materials, are disposed of except for those used for the production of service parts.

  Furthermore, as described above, the surplus inventory whose sales prospects have disappeared becomes a disposal loss also on the sales side such as the sales base 22 and the sales department 23.

  Further, with reference to the EOL stage information described above, remaining demand forecast information in the remaining life cycle from the beginning of the unit period to the EOL of the EOL product is formulated. The remaining demand prediction information includes a schedule until the end of production for each destination of the product. This makes it possible to formulate a more detailed remaining demand forecast. For the remaining demand forecast information, an application program (demand forecasting tool) that realizes a known demand forecasting method that has been generally proposed is selected according to the product characteristics and used on the computer in addition to the factory SC model. And will be formulated.

  The simulation condition setting unit 9 simulates the simulation period, for example, to which unit period after the first unit period the simulation should be performed, the setting of parameters such as the initial inventory setting, the sales volume setting of the unit period, etc. Set the conditions.

  Based on the simulation data, the simulation condition, the remaining demand prediction information, the supplier information, and the supply part plan information, the simulation unit 10 performs factory simulation using a factory SC model on a computer.

  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, when ordering materials, materials with long delivery lead times may be ordered with the same number of order lots as before with information before product demand declines. 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, with reference to the remaining demand forecast information, when the demand decline is predicted, change the material procurement conditions and place an order, that is, the order that can reflect the remaining demand information more by reducing the number of lots ordered. It is possible to do. However, in this case, the material unit price increases.

  For this reason, in order to minimize the material disposal loss at the factory 201 during 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. This is also true for raw materials that are stocked at the supplier 26 and compensated for purchases by contract.

  The factory simulation minimizes the total disposal cost of the material and the excess stock of the raw materials at the factory and supplier at the time of EOL of the product, considering the supply parts plan without causing product shortage at the factory level. The safety stock quantity of materials and raw materials is derived. At the same time, material procurement conditions and temporary logistics routes are selected. The temporary distribution route is considered as a countermeasure when, for example, the product goes to EOL, the prospective production becomes difficult at the supplier 26, and the delivery lead time becomes long, and the delivery lead time is shortened.

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

  If the result evaluation unit 11 evaluates and examines the result of the factory simulation, and further needs to change the conditions for simulation, the simulation condition setting unit 9 can set the conditions again and perform the simulation. Thereby, the range of evaluation can be expanded.

  The factory simulation result information is fed back as the safety stock number setting value or the safety stock day setting value and the disposal cost, stored in the database 1, and further transferred to the ERP package 2 for storage. The factory 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.

  By the factory simulation, it is possible to optimize the safety stock quantity of materials and raw materials in each factory and reduce the waste loss. The optimization of the safety stock number of materials and raw materials and the reduction of disposal loss in units of factory SC models effectively function for dedicated materials limited to the units of factories.

  Next, the model creation unit 12 combines a plurality of factory SC models and sets an integrated SC model (integrated SC model).

  The integrated SC model is a model that performs a simulation (integrated simulation) that links the above-described plurality of factory SC models and optimizes common materials (including raw materials) between the factories. From the information on production status of products at each factory 201, for example, whether it is continuous production or a decrease in production toward EOL, inventory of materials, order status, and information on inventory status of materials and raw materials at suppliers 26, etc. The number of safety stocks of common materials and the stock location, the derivation of the distribution route of common materials, and the function of reducing waste loss during EOL of products.

  The simulation condition setting unit 13 sets parameters such as the simulation period, to which unit period after the initial unit period the simulation is to be performed, the setting of the initial safety stock quantity of common materials, the setting of the production amount of the unit period, etc. , Etc. are set.

  Based on the simulation data, information derived from factory simulation, remaining demand prediction information, supplier information, and supply parts plan information, the simulation unit 14 performs simulation using an integrated SC model on a computer.

  Integrated simulation minimizes the total waste disposal cost of common stock at factories and suppliers at the time of product EOL, considering supply parts planning, without causing shortages of common materials throughout the entire factory. The safety stock number of common materials is derived. At the same time, the breakdown of the number of safety stocks in a plurality of factories 201, that is, the number of stocks in each factory is derived.

  However, the breakdown of the plurality of factories 201 may be different from the number of safety stocks of the factories 201 in the simulation in the factory unit, that is, the factory SC model. This is due to changes in product production plans at each factory, differences in life cycle stages, and the like. For example, the product of the first factory becomes EOL and the production is stopped, and the product of the second factory is in constant production.

  In this case, in the simulation for each factory, the number of safety stocks that minimize the disposal loss is derived for each of the first factory and the second factory even if they are common materials. As described above, since the reduction of the waste loss is limited to the scope of each factory, for example, the waste loss of the first factory is processed in the first factory, and further reduction is attempted. It is difficult.

  On the other hand, in the simulation between the whole factories, the number of safety stocks through the whole factories, for example, the first factory and the second factory is derived, and the disposal loss is derived. For this reason, even if the product of the first factory becomes EOL and a loss of waste occurs, the loss of the waste can be reduced by applying it to the product of the second factory that is continuing production. However, for this purpose, it is necessary to move the common material that causes waste loss at the first factory to the second factory.

  In the integrated simulation, as described above, the number of movements of the common material that is transferred between the respective factories is derived simultaneously with the derivation of the number of stocks of the common material at each factory. In addition, a distribution route (factory distribution route) between factories used for this movement is set. This transfer of common materials includes changing the supply destination of materials for each factory in stock at the supplier 26.

  The result evaluation unit 15 evaluates and reviews the results of the integrated simulation (the entire inter-factory common material, the number of each plant's safety stock, the number of common material movements, the inter-factory logistics route), and the simulation needs to be changed under different conditions. The simulation condition setting unit 13 can set a condition again to perform a simulation. Thereby, the range of evaluation can be expanded.

  The information of the integrated simulation result is fed back as the common material safety stock number, the common material movement number, and the inter-factory distribution route, stored in the database 1, and further transferred and stored in the ERP package 2. Furthermore, it is reflected in the supply chain 20.

  In the simulation with the factory SC model and the integrated SC model described above, the information and communication environment information of the bases constituting the supply chain from the database 1 and information on the state of operation stability, communication environment information, and smooth logistics It is preferable to carry out a simulation by taking out and taking into account logistics information relating to the state such as speed. This makes it possible to perform a simulation that is closer to the actual system and with high accuracy.

  Furthermore, each plan including a sales plan is created according to the actual demand (order) of the customer 21 in the supply chain 20, and the above-mentioned simulation is performed in consideration of the remaining demand forecast and the service part demand forecast in the product life cycle. And a series of optimization processes for optimizing the supply chain 20 are performed in a cycle every predetermined period and reflected in the supply chain 20.

  The cycle for each predetermined period is set to any one of the target products every time a change in actual demand (actual sales fluctuation) of the customer 21 occurs in the supply chain 20 in any of the target products. Each time there is a change in the life cycle stage, or a combination thereof. The predetermined period is preferably set as appropriate in consideration of the market position of the target product, demand, characteristics, product life, and the like. In addition, when any product is in a decline period, that is, close to EOL, it is preferable to shorten the predetermined period.

  As described above, a factory SC model on a computer based on simulation data and simulation conditions, remaining demand forecast information, supplier information, and spare parts planning information at each point in the life cycle of a plurality of products produced at a plurality of factories. A factory simulation is performed.

  Next, based on simulation data, factory simulation information, remaining demand forecast information, supplier information, and spare parts plan information, an integrated SC model is used on a computer, and it is commonly used among multiple products at multiple factories. Perform integrated simulation on common materials.

  Further, these simulations are carried out at a cycle for each predetermined period.

  As a result, it is possible to optimize the safety stock number of dedicated materials limited to each product or each factory without causing a shortage, and to reduce the disposal loss of the dedicated materials at the time of product EOL. Furthermore, it is possible to optimize the safety stock number of common materials and the inventory location including the movement of common materials to reduce the loss of disposal of common materials.

  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 the EOL product and the next product according to the actual demand of the customer 21 in the supply chain 20 are created.

  In step S102, the supplier information creation unit 43 creates supplier information including material inventory information at each supplier 26, the number of raw materials in stock and the number of orders, raw material common information, raw material production end information, and procurement contract information.

  In step S <b> 103, a supply parts plan creation unit 44 creates a service parts supply part plan used for product after-sales service. The supply parts plan includes forecast and confirmation information.

  In step S104, the data conversion unit 7 creates simulation data based on product information, production information, distribution route information, material information, material procurement condition information, and sales / demand / production plan information.

  In step S105, the model creation unit 8 creates a supply chain model (factory SC model) in which the supply chain is modeled on a computer basis on the computer based on information such as the supply chain configuration stored in the database 1. Further, with reference to the EOL stage information, remaining demand forecast information in the remaining life cycle from the beginning of the unit period of the EOL product to the EOL is formulated.

  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 factory-based simulation (factory simulation) using a factory SC model on a computer based on simulation data and simulation conditions, remaining demand prediction information, supplier information, and supply part plan information. .

  In step S108, the result evaluation unit 11 evaluates and examines the result of the factory simulation, and when it is necessary to change the conditions and perform 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 process proceeds to step S109.

  In step S109, the factory simulation result is fed back as the safety stock number setting value or the safety stock day setting value and the disposal cost, and stored in the database 1.

  In step S110, the simulation result (safety stock number setting value or safe stock days setting value and disposal cost) 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 is taken into the supply chain 20 and reflected in an actual product inventory plan, material requirement plan creation, order confirmation, and forecast.

  In step S112, the model creation unit 12 combines a plurality of factory SC models, and an integrated SC model (integrated SC model) is set. The integrated SC model is a model that performs a simulation (integrated simulation) that links the above-described plurality of factory SC models and optimizes common materials (including raw materials) between the factories. From the information on production status of products at each factory 201, for example, whether it is continuous production or a decrease in production toward EOL, inventory of materials, order status, and information on inventory status of materials and raw materials at suppliers 26, etc. The number of safety stocks of common materials and the stock location, the derivation of the distribution route of common materials, and the function of reducing waste loss during EOL of products.

  In step S113, the simulation condition setting unit 13 sets the simulation conditions by the person in charge. The simulation conditions are set such as the simulation period, the unit period after the initial unit period, etc., and the setting of parameters such as the initial safety stock number of common materials and the production amount of the unit period. , Etc.

  In step S114, the simulation unit 14 performs simulation (integrated simulation) using an integrated SC model on a computer based on the simulation data, information derived from factory simulation, remaining demand prediction information, supplier information, and supply parts plan information. Is done.

  The common simulation that minimizes the total cost of disposal of excess stock of common materials at the factory and supplier at the time of EOL of the product, considering the replacement parts plan without causing a shortage of common materials throughout the entire factory in the integrated simulation The number of material safety stocks is derived. At the same time, the breakdown of the number of safety stocks in a plurality of factories 201, that is, the number of stocks in each factory is derived. In addition, the number of movements of the common material to be transferred between the factories is derived, and a distribution route between the factories (an inter-factory distribution route) used for the movement is set.

  In step S115, the result evaluation unit 15 evaluates and examines the results of the integrated simulation (the entire inter-factory common material, the number of each plant's safety stock, the number of common material transfers, and the inter-factory distribution route). If it is necessary to change the conditions for further simulation (step S115; No), the conditions are set again in step S113 and the simulation is performed. If re-simulation is not required (step S115; Yes), the process proceeds to step S116.

  In step S116, the result of the integrated simulation is fed back as the common material safety stock number, the common material movement number, and the inter-factory distribution route, and stored in the database 1. Stored in database 1.

  In step S117, the result of the integrated simulation (safety stock number setting value or safe stock days setting value and disposal cost) 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 S118, the result of the integrated simulation is taken into the supply chain 20 and reflected in an actual product inventory plan, material requirement plan creation, order confirmation, and forecast.

  The processing from the above steps S101 to S118 is performed at a cycle for each predetermined period.

DESCRIPTION OF SYMBOLS 1 Database 2 ERP package 3 Sales plan 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 part 11, 15 Result evaluation part 20 Supply chain 21 Customers 22 Sales bases 23 Sales departments 24 Production departments 25 Material procurement departments 26 Suppliers 41 Demand planning departments 42 Base warehouses 43 Supplier information creation departments 44 Supply parts planning departments

Claims (10)

When the sales plan for sales of products that include common materials used in the materials to be used and produced at multiple factories and the demand plan for product procurement shift from future prospect information (forecast information) to final information A supply chain efficiency support method for improving the efficiency of the supply chain of the product consisting of a plurality of operations ranging from procurement of materials that may fluctuate through production processes to customers,
A step of integrating a supply chain model in which the supply chain is modeled in a factory unit, a supply chain model in the factory unit, and an integrated supply chain model on a computer;
Creating the sales plan at the beginning of a unit period of the product in the supply chain, the demand plan based on the sales plan, and producing a production plan based on the demand plan and storing it as storage information in each storage means;
Predicting the demand in the remaining period from the beginning of the product to the end of production in the life cycle of the product, and storing it in storage means as residual demand prediction information;
The supplier that supplies the material to the material procurement side, based on the number of the material and the raw material used for the material, information about the material and the product that is the target of the material, material production end information, and procurement contract information Creating information and storing it in a storage means;
Establishing supply parts plan information assuming the demand for service parts used for after-sales service of the product, and storing it in the storage means;
Based on product information, production information, distribution route information, material information, material procurement condition information, and sales, demand, and production plan information stored in an ERP (Enterprise Resource Planning) package, simulation data is created by simulation data creation means. Creating and storing in the storage means;
Based on the simulation data, the remaining demand forecast information, the supplier information, and the supply part plan information, the factory unit simulation is performed on the computer in the factory unit supply chain model. Deriving the selection of the material, the safety stock number of the raw material and the distribution route that minimize the total disposal cost of the material and the surplus stock of the raw material at the factory and supplier at the end of production without causing shortage; and ,
In the integrated supply chain model, based on the information derived in the factory unit simulation, the remaining demand forecast information, the supplier information, and the supply parts plan information for common materials used in common among the products, The number of safety stocks and the number of transfers between factories that minimize the waste disposal cost of the common stock at the factory and suppliers at the end of production without causing a shortage of the product by performing simulation on the computer A method for deriving a distribution route between factories, and a series of processing in the step is performed at a cycle every predetermined period.   2. The supply chain efficiency support method according to claim 1, wherein the plurality of operations include material procurement operations, production operations, sales operations, sales base operations, and logistics operations related to the respective operations.   3. The supply chain efficiency support method according to claim 1, wherein the sales plan, the demand plan, and the production plan each include a plan for each destination.   4. The supply chain efficiency support method according to claim 1, wherein the remaining demand prediction information includes a schedule until the end of production for each destination of the product. 5.   The supplier information includes the number of stocks of the material in the supplier, the number of stocks and order lots of raw materials used for the material, the raw material common information indicating whether the raw material is dedicated to the product or common with other products, the raw material production end The supply chain efficiency support method according to any one of claims 1 to 4, further comprising information and procurement contract information.   The material information includes information on whether the material is a dedicated material for the product or a common material with other products including the next product, and the material procurement condition information includes the number of lots ordered, the material unit price, The supply chain efficiency support according to any one of claims 1 to 5, including data on 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. Method.   The supply chain according to any one of claims 1 to 6, wherein the product information includes material to be used, quantity of the material, process chart, and configuration data for each destination of the product. Efficiency support method.   The production information includes the production amount information of the product and the production plan information of the delivery date, the change of the production amount and the delivery date of the product when the next product is put on the market, the information of the production plan, the stock information of the material, the order information and the delivery date information. The supply chain efficiency support method according to any one of claims 1 to 7, further comprising: price information, product inventory information in production and sales.   The supply chain efficiency support method according to any one of claims 1 to 8, 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 9.

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