JP4325825B2 - Production plan control method, production plan system, and recording medium - Google Patents

Description

ここで、在庫は在庫ＤＢに登録されている在庫量を表し、手配残は製造計画の手配済で製造依頼済の数量を表し、所要量は図５の（ｂ）の受注オーダを製造するときに必要な所要量（部品Ａが１００．部品（購買品）Ｐが１００という所要量）を表し、正味所要量は所要量から在庫、手配残を引き当てた不足分の所要量を表し（ここでは、部品Ａは、（所要量１００−在庫０−手配残１００）＝１００となる）、ロットまるめは既述した図５の（ｂ）の品番ＤＢの製造ロットサイズにまるめを表す（例えば部品（購買品）Ｐは正味所要量６０であるが製造ロットサイズ１００であるのでロットまるめ１００となる）。
【００５１】
図５の（ｄ）は、製造オーダの例を示す。この製造オーダは、図５の（ｃ）のロットまるめで決定された生産オーダのうち、製品Ｘ，Ｙ、および製品を製造するために必要な部品（購買品である部品Ｐを除いた製造する必要のある部品）を、ここでは、製造オーダとしたものであって、図示の下記の項目を格納したものである。
【００５２】
・製造オーダテーブル：
・製造オーダＮＯ：
・品番：
・数量：
・納期：
図５の（ｅ）は、ロット分割の例を示す。これは、図５の（ｄ）で決定した製造オーダについて、ロットに分割したものである。ここでは、図示の下記のロットに分割される。
【００５３】
製品／部品名：個数 ロット番号−サブ番号 製品／部品の数量
Ｘ製品 ：１００ Ｓ００１−００１ Ｘ１００
Ｙ製品 ：１００ Ｓ００２−００１ Ｙ１００
Ａ部品 ：１００ Ｓ００３−００１ Ａ１００
図５の（ｆ）は、工程展開の例を示す。これは、図５の（ｅ）のロット分割した後の各ロットについて、１つの工程、あるいは２つの工程で製造されるときは図示のようにそれぞれ各工程に展開する。
【００５４】
以上の図５の（ａ）から（ｆ）によって、受注オーダについて、所要量計算、製造オーダ決定、ロット分割、工程展開することが可能となる。そして、図６から図９の手順で割り付けし、資材計画と資源計画を同時に考慮した製造計画を自動的に作成することが可能となる。
【００５５】
図６から図９は、本発明の動作説明図を示す。ここでは、バックワード割付けを例に以下詳細に説明する。
図６の（ａ）は、手配残の割付け例を示す。これは、手配残の割付けの例であって、割付け対象として、
・▲１▼の部分に、既述した図５の（ｆ）の工程展開した▲１▼ロットを配置
・▲２▼の部分に、手配残（部品Ａを１００個製造するという手配残）を配置
する。
【００５６】
そして、▲２▼の部分の手配残（部品Ａを１００個製造するという手配残）のオーダ（ロット）を▲２▼’の矢印で示すように、製造計画上に最初に配置する。尚、手配残がないときは、図６の（ａ）は、スキップし、図７の（ｂ）に進む。
【００５７】
また、下段の在庫ＤＢには、部品Ａの在庫の内容が▲２▼’の配置により図示の下記のように格納される（初期在庫は０である）。
また、下段の部品Ａの在庫ＤＢには、部品Ａの在庫の内容が図示の下記のように格納されている。
【００５８】
月日 ７月１７日 ７月１８日 ７月１９日 ７月２０日
使用数 ０ ０ ０ ０
製造数 １００ ０ ０ ０
在庫数 １００ １００ １００ １００
ここで、使用数は製品／部品の製造に使用した数を表し、製造数は製造した数を表し、在庫数は現在月日の在庫数を表す。
【００５９】
図７の（ｂ）は、ローレベル”０”のオーダを割り付ける。ここでは、ローレベル”０”（最上位）の最早の納期の▲３▼、▲３▼’を選択し、納期日から前に向かって図示のように順に割り付ける。
【００６０】
また、下段の部品Ａの在庫ＤＢには、▲３▼，▲３▼’を割り付けたことで、部品Ａを１００個使用し、在庫の内容が下記の＊の部分が図示のように格納（更新）される。
【００６１】
月日 ７月１７日 ７月１８日 ７月１９日 ７月２０日
使用数 ０ ＊１００ ０ ０
製造数 １００ ０ ０ ０
在庫数 １００ ＊０ ＊０ ＊０
図８の（ｃ）は、ローレベル”０”のオーダを納期順に割り付ける。ここでは、ローレベル”０”の次の最早の納期の▲４▼、▲４▼’を選択し、納期日から前に向かって図示のように順に割り付ける。
【００６２】
また、下段の部品Ａの在庫ＤＢには、▲４▼，▲４▼’を割り付けたことで、部品Ａを１００個使用、部品（購入品）Ｐを１００個使用し、在庫の内容が下記の＊の部分が図示のように格納（更新）される。
【００６３】
部品Ａの在庫ＤＢ
月日 ７月１７日 ７月１８日 ７月１９日 ７月２０日
使用数 ０ １００ ＊１００ ０
製造数 １００ ０ ０ ０
在庫数 １００ ０ ＊−１００ ０
部品Ｐの在庫ＤＢ（初期在庫４０とする）
月日 ７月１７日 ７月１８日 ７月１９日 ７月２０日
使用数 ０ ０ ＊１００ ０
製造数 ０ ０ ０ ０
在庫数 ４０ ４０ ＊−６０ ＊−６０
ここで、部品Ａは、＊−１００の部分で在庫不足が発生していることが判明する。部品Ｐはリードタイムを２日としているため、７月１９日に間に合うように、７月１７日に購買品の発注を別途行なうことで間に合うことで、部品Ｐの供給に支障がでないと判明する。
【００６４】
以上のことより、部品Ａについて、製品Ｙの▲３▼’の配置した月日（７月１９日）以前に不足部品Ａを製造（配置）する必要があると判明する（図９の▲５▼の配置をする必要があると判明する）。
【００６５】
図９の（ｄ）は、在庫補充のための割付け例を示す。ここでは、図８の（ｃ）の▲４▼、▲４▼’の配置（製品Ｙの配置）により、部品Ａが６０個不足する判明したことに対応して、▲５▼の矢印で示すように部品Ａの製造を配置することにより、下段の部品Ａの在庫ＤＢには、
月日 ７月１７日 ７月１８日 ７月１９日 ７月２０日
使用数 ０ １００ １００ ０
製造数 １００ ０ １００ ０
在庫数 １００ ０ ０ ０
となり、在庫不足が解消されたこととなる。
【００６６】
図９の（ｅ）は、計画配置時の在庫数の計算ルールの例を示す。
・資材を消費する場合：計画の開始時間（段取り時間を含まない）の含まれる日からマイナスする。
【００６７】
・資材を製造する場合：計画の終了時間の含まれる日の次の日にプラスする。
以上の図６から図９の手順によって、図５の（ｂ）の受注オーダ（製品Ｘ，１００個、製品Ｙ，１００個の受注オーダ）について、図５の（ｆ）の工程展開後のロット（オーダ）をもとに納期日の速い順に納期日から前に向かって割り付けると共に在庫部品が不足するときはその部品の製造を割り付けたり、購入を依頼したりすることにより、資材計画と資源計画を同時に考慮して無駄な在庫の発生をなくした割付けを自動的に行なうことが可能となる。
【００６８】
図１０から図１２は、本発明の説明図を示す。
図１０の（ａ）は、ローレベル毎の割付け例（従来）を示す。この従来のローレベル毎の割付けを行なうと、
・製品Ｘ，１０００個
・製品Ｙ，１０００個
・製品Ｘ，１０００個
・製品Ｙ，１０００個
・部品Ａ．２０００個
・部品Ａ，２０００個
という順に納期の１０（土）からバックワードで割り付けるため、下段の部品Ａの在庫量を見て判明するように、無駄な在庫量（製品Ｘ，Ｙの製造に使用されるまでの無駄な在庫量）が多いという欠点がある。
【００６９】
図１０の（ｂ）は、コンカレントスケジュール（本願発明）の例を示す。ここでは、既述したように最早納期のローレベルの製品、その製品の製造に使用する部品の順に割り付ける（図示例では、（製品Ｘ：１０００個、製品Ｙ：１０００個、その部品Ａ：２０００個）を２回繰り返す）ことで、図示の
・製品Ｘ，１０００個
・製品Ｙ，１０００個
・部品Ａ．２０００個
・製品Ｘ，１０００個
・製品Ｙ，１０００個
・部品Ａ．２０００個
という順に納期の１０（土）からバックワードで割り付けるため、下段の部品Ａの在庫量を見て判明するように、無駄な在庫量（製品Ｘ，Ｙの製造に使用されるまでの無駄な在庫量）が、図１０の（ａ）に比して２／１０＝１／５に削減されるという特徴がある。
【００７０】
図１１の（ｃ）は、ローレベル毎の割付け例（従来）を示す。ここでは、
計画条件：最遅納期、バックワード
で割り付けたときの様子を▲１▼から▲６▼で示す。部品表は、右上に記載した通りとする。
【００７１】
最遅納期が６月１０日であるので、
・▲１▼製品Ｙ、１０００個
・▲２▼製品Ｘ，１０００個
・▲３▼製品Ｙ，１０００個
・▲４▼製品Ｘ，１０００個
とバックワード割付けとなり、日数が開始日になってしまい、これら製品Ｘ，Ｙを製造するために必要な部品Ａが▲５▼、▲６▼に配置され、これでは、▲１▼から▲４▼の全製品Ｘ，Ｙの１００％が実行不可能な製造計画となってしまう欠点がある。
【００７２】
図１１の（ｄ）は、コンカレントスケジュール（本願発明）の例を示す。ここでは、図１１の（ｃ）と同じ計画条件（最遅納期、バックワード）で割り付けても、既述したようにローレベルの製品、その製品の製造に使用する部品の順に割り付ける（図示例では、（製品Ｙ：１０００個、製品Ｘ：１０００個、その部品Ａ：２０００個）ことで、図示の
・▲１▼製品Ｘ，１０００個
・▲２▼製品Ｙ，１０００個
・▲３▼部品Ａ．２０００個
という順に納期の１０（土）からバックワード割付けできる。そして、残りの
・▲６▼製品Ｘ，１０００個
・▲５▼製品Ｙ，１０００個
・▲４▼部品Ａ．２０００個
については、納期の１０（土）を最終日としてバックワード割り付けるすると、６月１４日（水）の４日遅れの製造計画が立案できることが判明する。この結果、５０％の製品Ｘ，Ｙが納期日までに製造できる製造計画が立案でき、図１１の（ｃ）の全部の製品Ｘ，Ｙが納期日までに製造できない場合に比して大幅に改善されることが判明する。
【００７３】
図１２の（ｅ）は、ローレベル毎の割付け例（従来）を示す。ここでは，ローレベル毎に納期（１０土）からバックワード割付けすると、
・▲１▼製品Ｘ、１０００個
・▲２▼製品Ｙ，１０００個
・▲３▼製品Ｘ，５００個
・▲４▼製品Ｙ，５００個
・▲５▼部品Ａ，１０００個
・▲６▼部品Ａ，１０００個
とバックワード割付けとなり、日数が開始日になり、
・▲７▼部品Ａ，１０００個
が納期（１０土）の次の日（１１日）になってしまい、結果として、▲１▼製品Ｘ，１０００個と▲７▼部品Ａ，１０００個が実行不可能な製造計画となる（▲１▼製品Ｘ、１０００個が納期までに製造できない製造計画となる）という欠点がある。
【００７４】
図１２の（ｆ）は、コンカレントスケジュール（本願発明）の例を示す。ここでは、図１２の（ｅ）と同じ計画条件で割り付けても、既述したようにローレベルの製品、その製品の製造に使用する部品の順に割り付けると、
・▲１▼製品Ｘ，１０００個
・▲２▼部品部Ａ，１００個
・▲３▼製品Ｙ，１０００個
・▲４▼部品Ａ，１０００個
・▲５▼製品Ｘ，５００個
・▲６▼製品Ｙ，５００個
・▲７▼部品Ａ，１０００個
という順に納期の１０（土）からバックワード割付けでき、１００％の製品Ｘ、Ｙの製造が可能な製造計画を立案できるという特徴がある。
【００７５】
【発明の効果】
以上説明したように、本発明によれば、資材計画と資源計画を同時に計画することで無駄な在庫を削減することが可能となる。これにより、
（１） 在庫の削減
（２） 製造リードタイムの短縮
（３） 柔軟な製造計画の変更が可能
（４） 納期厳守率の工場
（５） 生産計画の作成工数の削減
を図ることができる。
【図面の簡単な説明】
【図１】本発明のシステム構成図である。
【図２】本発明の動作説明フローチャートである。
【図３】本発明の詳細動作説明フローチャート（所要量計算）である。
【図４】本発明の詳細動作説明フローチャート（割付け）である。
【図５】本発明の説明図である。
【図６】本発明の動作説明図（その１）である。
【図７】本発明の動作説明図（その２）である。
【図８】本発明の動作説明図（その３）である。
【図９】本発明の動作説明図（その４）である。
【図１０】本発明の説明図（その１）である。
【図１１】本発明の説明図（その２）である。
【図１２】本発明の説明図（その３）である。
【符号の説明】
１：データベース
２：受注データデータベース
３：手配残データベース
４：在庫データデー巣
５：品番データベース
６：部品表データベース
７：製造計画データベース
８：発注計画データベース
１０：メモリテーブル
１１：マスタ情報テーブル
１２：オーダ情報テーブル
１３：計画結果テーブル
１７：所要量計算手段
２２：スケジューリング手段
３１：処理手段[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a production plan control method for creating a product production plan, a production plan system, and a recording medium.
[0002]
[Prior art]
Conventionally, a production plan for producing a product first creates a standard production plan, and calculates the required amount of parts and materials based on this. Based on these calculated requirements, a small schedule production plan that takes into account the capacity of the equipment to produce the product was created, and when the created small schedule production plan was overloaded, it was redone from the standard production plan. .
[0003]
In the prior art, in the process of assigning all the low-level items as described in FIG. 10, FIG. 11, and FIG. 12, a product production plan is first created and the product is delivered in time for the product delivery date. Next, the production plan is created by calculating the required amount of the product. Therefore, in the example described with reference to FIG. 10, the product X is set to be delivered to 6/8 and 6/10, and the product Y is set to be delivered to 6/7 and 7/9. Next, the parts constituting the product are arranged in time for the production line and in the idle time of the production line. In FIG. 10, since the products X and Y use the part A, an order for manufacturing the part A is created. However, since the order of the products X and Y is already arranged in the equipment 1 line. 6 / 4-5 and 6 / 5-6. In such a case, the product order is placed first, so the schedule is such that all parts are prepared in advance, and the warehouse has a wasteful inventory that is not used on the production line of the day. It was.
[0004]
Further, in the case of the example described in FIG. 11, since the delivery date of all orders is 6/10, the product X is arranged on 6/7, 6/9, and the product Y is arranged on 6/8, 6/10. The Next, for the parts constituting the product, an attempt is made to arrange an order corresponding to the lead time of each part in time for the production date of the product, but since the operation period of the equipment is from 6/7, 6/11 It will be placed after that. In such a case, since the product order is first placed, it becomes impossible to prepare the parts that make up the product within the operation period of the equipment, and the schedule is infeasible for all products.
[0005]
Further, in the case of the example described in FIG. 12, since the delivery date of all orders is 6/10, the product X is arranged at 6/8, 6/10, and the product Y is arranged at 6/7, 6/9. The Next, for the parts that make up the product, an attempt is made to set the order according to the lead time of each part in time for the product manufacturing date. However, considering the equipment operation period, set it before the product delivery date. This is difficult, and the order of some parts is to be set after the delivery date of the product, and the product X for the 6/10 delivery date has no schedule because it has no parts.
[0006]
[Problems to be solved by the invention]
In the conventional technique, a production plan for a product is first created, a product order is set in time for the delivery date of the product, and then a production plan is created by calculating the required amount of parts. Therefore, it is not possible to plan for parts (lower level) unless all products (upper low level) are assigned instead of assigning products and parts to the plan in parallel. For this reason, even if a production plan is made once, it is often redone, and a lot of time is required to make a production plan.
[0007]
[Means for Solving the Problems]
Therefore, in the present invention, the total required amount of parts used for the entire product is obtained before planning, and then divided into lots which are predetermined units set for each part. Is also assigned to the production plan in parallel with the product order.
[0008]
Means for solving the problem will be described with reference to FIG.
In FIG. 1, the required amount calculation means 17 calculates the required amount of parts.
[0009]
The scheduling means 22 performs a schedule.
The processing means 31 performs various processes, and collects the product lots based on the quantity of products instructed for production.
[0010]
Next, the operation will be described.
The processing means 31 summarizes the product lots based on the quantity of the products for which production is instructed, calculates the required amount of necessary parts based on the product lots compiled by the required quantity calculation means 17, and the scheduling means 22. Based on the required amount of parts calculated by the above, the inventory or the inventory and the remaining arrangements are allocated, and the parts in the lot unit order for the shortage parts are collected.
[0011]
Further, based on the shortage part order compiled by the scheduling means 22, the process is expanded to the process for manufacturing the part, and each process of the expanded part order is assigned, and is necessary for each process of the assigned part order. The inventory of parts or the inventory and the remaining arrangements are checked, and if there is a shortage, the missing parts are assigned.
[0012]
In these cases, if there are products, parts necessary for manufacturing the products, and parts required for manufacturing the parts, they are assigned in order from the top.
In addition, the parts necessary for manufacturing the products in order of the delivery date of the products, and when there are parts necessary for manufacturing the parts, the parts are allocated in time.
[0013]
In addition, when there are orders for a plurality of parts when allocating, they are sequentially allocated according to a priority order designated in advance.
Therefore, it is possible to reduce wasteful inventory by simultaneously planning the material plan and the resource plan.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments and operations of the present invention will be described in detail sequentially with reference to FIGS.
[0015]
FIG. 1 shows a system configuration diagram of the present invention.
In FIG. 1, a database 1 stores data in an easily searchable manner, and is composed of 2 to 8 here.
[0016]
The order database 2 stores information on products ordered from customers.
The remaining arrangement database 3 stores information on the remaining arrangement products and parts.
[0017]
The stock database 4 stores product and part stock information.
The product number database 5 stores information such as part items, rounded sizes, and manufacturing lot sizes (see FIG. 5).
The parts table database 6 stores parts necessary for manufacturing products (see FIG. 5).
[0018]
The production plan database 7 stores a production plan.
The order plan database 8 stores an order plan.
The DB interface 9 is an interface for accessing the database 1.
[0019]
The memory table 10 is a variety of tables provided on the memory, and here stores a master information table 11, an order information table 12, a plan result table 13, and the like.
[0020]
The master information table 11 stores information such as products and parts constituting the products.
The order information table 12 stores various orders.
[0021]
The plan result table 13 stores plan results.
The order information 14 is product order information from a customer.
The delivery date answering means 15 refers to the memory table 10 based on the order information 14, takes out the delivery date of the product, and replies to the customer (salesman).
[0022]
The plan execution instructs the creation of a product plan schedule.
The required amount calculation means 17 calculates the required amount of necessary parts based on the product lot.
[0023]
The order order creating means 18 creates an order order.
The ordering order 19 stores the created ordering order.
The Gantt chart means 20 displays the plan result 13 on the Gantt chart for easy viewing.
[0024]
The Gantt chart 21 is a Gantt chart of the plan results displayed and printed.
The scheduling means 22 creates a production plan based on the required amount calculated by the required amount calculating means 17 in accordance with the plan condition 23 (see FIGS. 3 to 5).
[0025]
The processing means 31 performs various processes, and collects the lots of the products based on the quantity of the ordered products.
Next, the overall operation of the configuration of FIG. 1 will be described according to the order of the flowchart of FIG.
[0026]
FIG. 2 shows a flowchart for explaining the operation of the present invention.
In FIG. 2, S1 registers a parts table. For example, a parts table storing information of parts necessary for manufacturing the product of FIG. 5A described later is registered.
[0027]
In S2, a product number master is registered. For example, a product number DB (product number master) in which information such as a size and a manufacturing lot size is stored in association with a product number of a part shown in FIG.
[0028]
S3 accepts an order receipt. This accepts orders for products from customers (salesmen).
In S4, the required amount is calculated. This is based on the detailed flowchart of FIG. 3 to be described later. The product lots are grouped into product lots based on the product quantity indicated in the order received in S3, and the required amount of parts required based on the collected product lots. And so on. Here, based on the required amount, the inventory or the inventory and the remaining arrangements are allocated and the missing parts are grouped into lot orders.
S5 outputs the production order. This outputs a production order for producing the required amount calculated in S4.
[0029]
S6 creates a production order. This creates a manufacturing order that is actually manufactured based on the production order output in S5.
In S7, the lot is divided. This is divided into production lot sizes in the product number master.
[0030]
In S8, the process is expanded. This is developed for each process when a part is manufactured in a plurality of processes for the lot after the lot is divided in S7.
S9 is assigned. According to the detailed flowchart of FIG. 4 to be described later, backward allocation is performed in order from the top, and a production plan is created.
[0031]
By the above, after calculating the required amount based on the order received, dividing the lot, developing the process, creating a production plan by assigning backwards, etc., it is possible to plan the material plan and resource plan at the same time, It is possible to reduce useless inventory and to create an appropriate plan. Details will be sequentially described below.
[0032]
FIG. 3 shows a detailed operation explanation flowchart (required amount calculation) of the present invention.
In FIG. 3, S11 is rounded to a product lot. For example, the order of FIG. 5B (to be described later) is received, and the quantity of products (for example, 80 pieces) is rounded to the production lot size (for example, 100 pieces / lot) with reference to the component DB.
[0033]
In S12, the required amount is calculated. In S11, after rounding into a production lot, the required amount of parts necessary for producing the product is calculated with reference to the parts table of FIG. 5A based on the production lot.
[0034]
S13 allocates inventory / arrangement remaining. This refers to the inventory database, allocates the inventory and then the remaining arrangement for the required amount of parts calculated in S12, and calculates the shortage required amount.
[0035]
In step S14, the part lot is rounded. This is rounded to the part lot for the required amount of the part calculated in S13. Here, lot division and process development are performed.
In S15, the lot is divided. This is divided for each lot of parts rounded in S14.
[0036]
In S16, it is determined whether there is a lower part. If yes, return to S12 and repeat. If NO, the process ends.
By the above, after rounding into a production lot based on the order received, calculating the required amount of parts necessary for this, the remaining shortage is rounded up to the parts lot by allocating the remaining inventory and hand loss, and by dividing the lot, It is possible to automatically create a part order for the shortage by calculating the required amount of each part and allocating the inventory and the remaining arrangement. Here, it is a feature of the present invention that the required amount in the entire planning period is obtained and divided into appropriate lots.
[0037]
FIG. 4 shows a detailed operation explanation flowchart (assignment) of the present invention.
In FIG. 4, S21 selects an order. For example, in the case of backward allocation, one higher-order order (product order) with a quick delivery date is selected.
[0038]
In S22, the order is allocated. For example, in the case of backward allocation (post-loading), the product orders with the quick delivery date selected in S21 are allocated in order toward the delivery date.
[0039]
In the case of forward allocation (previous loading), forward allocation is performed backward from the scheduled start date. In the case of intermediate loading, backward allocation and forward allocation are performed centering on the scheduled start date (both forward and backward from the planned start date, both are the same or specified positions). To be assigned).
[0040]
In S23, the inventory of parts is checked. This checks for a shortage of planned inventory of parts necessary for manufacturing the order allocated in S22.
In S24, it is determined whether or not there is. In the case of YES, since it is determined that there is stock, the process proceeds to the next order in S21.
[0041]
In S25, parts are allocated. As in S22, either backward allocation, forward allocation, or forward / backward allocation is performed.
[0042]
In S26, the parts inventory is checked. This checks for a lack of planned inventory of the parts needed to produce the assigned order.
In S27, it is determined whether or not there is. If YES, the process proceeds to S28. In the case of NO, the process returns to S25, the missing parts are allocated, and S26 and subsequent steps are repeated.
[0043]
S28 determines whether there is a remaining order. If yes, return to S21 and repeat.
In addition, when assignment is impossible in S22 and S25 (when the production completion date is delayed from the delivery date),
-In backward allocation, if possible, the delivery date is delayed or the production start date is advanced. If there is still an order that does not meet the delivery date, an alarm is displayed on the order (parts) to notify the administrator.
[0044]
In forward assignment, the scheduled start date is accelerated, reassignment is repeated, and if there is an order that does not meet the delivery date even at the earliest designated scheduled start date, an alarm is displayed on the order (part) to notify the administrator.
[0045]
・ For forward / backward assignment, re-assignment is repeated with a faster scheduled start date or more assignments on the forward side, and if there is still an order (part) that does not meet the delivery date, an alarm is displayed on that order (part). Inform the administrator.
[0046]
As described above, by assigning orders and checking inventory and remaining arrangements, if there are missing parts, assigning the missing parts at the same time automatically creates a production plan that takes into account equipment capacity and parts inventory. It is possible to create a production plan by creating and reducing the inventory of useless parts.
[0047]
FIG. 5 shows an explanatory diagram of the present invention.
FIG. 5A shows an example of a parts table. The left side shows a tree structure with parts represented in a hierarchical structure, and the right side shows a parts table in which upper items and lower items are associated with each other. Here, both represent the following.
[0048]
-Product X is manufactured from part A.
Y product is manufactured from part A and part P (purchased product).
FIG. 5B shows an example of a production plan. The left side shows the order received, the right side shows the product number DB, and the lower right shows the related data table. These are stored in association with the following items shown in the figure.
[0049]
・ Order orders:
・ Order NO:
Item: Product name (for example, product X in FIG. 5A)
·quantity:
·Delivery date:
・ Part number DB:
・ Item: Product name, part name, etc.
-Item classification:
・ Required classification:
・ Round size: 100, for example
Production lot size: for example 100
-Related data table:
-Equipment name: Name of equipment that manufactures products and parts
・ Process:
-Ability: Time required for manufacturing (for example, it takes 30 seconds to make one)
FIG. 5C shows an example of required amount calculation. The illustrated requirement calculation table shows an example of the requirement calculation table for manufacturing the order received in FIG. 5B. Here, the following information shown in FIG. It is a table for calculating.
[0050]

Here, the stock represents the stock quantity registered in the stock DB, the remaining order represents the quantity that has been ordered and requested for production in the production plan, and the required quantity is for manufacturing the order received in FIG. 5B. (Requirements for parts A is 100. Parts (purchased goods) P is 100), and net requirements represent the shortage requirements from the required amount to which the inventory and arrangements are allocated (here, , Part A (required amount 100−stock 0−remaining arrangement 100) = 100), and the lot rounding represents rounding in the manufacturing lot size of the part number DB of FIG. 5B described above (for example, part ( Purchased goods) P is the net requirement 60 but the production lot size 100, so it becomes a lot round 100).
[0051]
FIG. 5D shows an example of a production order. This production order is produced by removing products X and Y and parts necessary for producing the product (part P which is a purchased product) out of the production orders determined by the lot rounding in FIG. Here, the necessary parts) are the production orders, and the following items shown in the figure are stored.
[0052]
・ Production order table:
・ Production order NO:
・ Part number:
·quantity:
·Delivery date:
FIG. 5E shows an example of lot division. In this case, the production order determined in (d) of FIG. 5 is divided into lots. Here, it is divided into the following lots shown.
[0053]
Product / part name: Quantity Lot number-Sub number Quantity of product / part
X product: 100 S001-001 X100
Y product: 100 S002-001 Y100
A part: 100 S003-001 A100
FIG. 5F shows an example of process development. When each lot after the lot division shown in FIG. 5E is manufactured in one process or two processes, each lot is developed as shown in the figure.
[0054]
As shown in FIGS. 5A to 5F, it is possible to calculate the required amount, determine the production order, divide the lot, and develop the process for the received order. Then, it is possible to automatically create a production plan that is assigned in accordance with the procedures of FIGS. 6 to 9 and that simultaneously considers the material plan and the resource plan.
[0055]
6 to 9 are diagrams for explaining the operation of the present invention. Here, the backward allocation will be described in detail as an example.
FIG. 6A shows an example of the arrangement remaining arrangement. This is an example of the allocation of remaining arrangements.
・ In the part of (1), the (1) lot developed in the process (f) of FIG.
・ Arrangement remainder (arrangement of 100 parts A to be produced) is placed in part (2).
To do.
[0056]
Then, the order (lot) of the remaining arrangement of the part (2) (remaining arrangement for manufacturing 100 parts A) is first arranged on the production plan as indicated by the arrow (2). If there is no remaining arrangement, step (a) in FIG. 6 is skipped and the process proceeds to step (b) in FIG.
[0057]
Further, the contents of the inventory of the part A are stored in the lower inventory DB as shown in the figure by the arrangement (2) (the initial inventory is 0).
Further, the contents of the inventory of the part A are stored in the inventory DB of the lower part A as shown below.
[0058]
July 17th July 18th July 19th July 20th
Number used 0 0 0 0
Number of production 100 0 0 0
Stock 100 100 100 100 100
Here, the used number represents the number used for manufacturing the product / part, the manufactured number represents the manufactured number, and the inventory number represents the inventory number of the current month.
[0059]
In FIG. 7B, an order of low level “0” is assigned. Here, (3) and (3) 'of the earliest delivery date of the low level “0” (the highest) are selected and assigned in order as shown in the figure from the delivery date to the front.
[0060]
Also, by assigning (3), (3) 'to the inventory DB of the lower part A, 100 parts A are used, and the contents of inventory are stored as shown in the following * Updated).
[0061]
July 17th July 18th July 19th July 20th
Number of uses 0 * 100 0 0
Number of production 100 0 0 0
Stock 100 * 0 * 0 * 0
In FIG. 8C, the order of low level “0” is assigned in order of delivery date. Here, (4) and (4) 'of the earliest delivery date next to the low level “0” are selected and assigned in order as shown in the figure from the delivery date to the front.
[0062]
Also, by assigning (4), (4) 'to the inventory DB of the lower part A, 100 parts A are used and 100 parts (purchased goods) P are used. * Is stored (updated) as shown.
[0063]
Inventory DB for parts A
July 17th July 18th July 19th July 20th
Number used 0 100 * 100 0
Number of production 100 0 0 0
Number of stocks 100 0 * -100 0
Inventory DB for parts P (assumed initial inventory 40)
July 17th July 18th July 19th July 20th
Number used 0 0 * 100 0
Number of manufactures 0 0 0 0
Stock 40 40 * -60 * -60
Here, it is found that the part A has a shortage of inventory at the portion of * -100. Since the lead time of the part P is 2 days, it is proved that the supply of the part P is not hindered by placing the purchase order separately on July 17 so as to be in time for July 19th. .
[0064]
From the above, it becomes clear that it is necessary to manufacture (arrange) the missing part A before the date (July 19) when the product A (3) is arranged for the part A ((5) in FIG. 9). It turns out that the arrangement of ▼ is necessary).
[0065]
FIG. 9D shows an allocation example for stock replenishment. Here, in response to the fact that 60 parts A are insufficient due to the arrangement of (4) and (4) '(the arrangement of product Y) in FIG. By arranging the manufacture of the part A in this way, the inventory DB of the lower part A
July 17th July 18th July 19th July 20th
Number of use 0 100 100 0
Number of production 100 0 100 0
Stock 100 0 0 0
Thus, the shortage of inventory has been resolved.
[0066]
(E) of FIG. 9 shows an example of a calculation rule for the number of inventory at the time of planned arrangement.
-When consuming materials: Decrease from the date when the start time of the plan (not including the setup time) is included.
[0067]
-When manufacturing materials: Add the day after the day that includes the end time of the plan.
6 to FIG. 9, the lot after the process development of FIG. 5F is performed for the order received (product X, 100 pieces, product Y, order received order of 100 pieces) of FIG. 5B. Based on (order), materials are allocated in the order from the due date in order from the due date, and when the parts in stock are insufficient, the production of the parts is assigned or purchase is requested. It is possible to automatically perform allocation without generating unnecessary inventory by simultaneously considering
[0068]
10 to 12 are explanatory diagrams of the present invention.
FIG. 10A shows an example of assignment for each low level (conventional). When this conventional low level assignment is performed,
・ Product X, 1000 pieces
・ Product Y, 1000 pieces
・ Product X, 1000 pieces
・ Product Y, 1000 pieces
-Parts A. 2000 pieces
・ Part A, 2000 pieces
Since it is assigned backward from 10 (Saturday) of the delivery date in order, useless inventory (useless inventory until it is used for the manufacture of products X and Y, as can be seen by looking at the inventory of the lower part A There is a disadvantage that the amount is large.
[0069]
FIG. 10B shows an example of a concurrent schedule (the present invention). Here, as described above, the low-level product with the earliest delivery date and the parts used for manufacturing the product are assigned in this order (in the example shown, (product X: 1000, product Y: 1000, part A: 2000). 2) is repeated twice)
・ Product X, 1000 pieces
・ Product Y, 1000 pieces
-Parts A. 2000 pieces
・ Product X, 1000 pieces
・ Product Y, 1000 pieces
-Parts A. 2000 pieces
Since it is assigned backward from 10 (Saturday) of the delivery date in order, useless inventory (useless inventory until it is used for the manufacture of products X and Y, as can be seen by looking at the inventory of the lower part A (Amount) is reduced to 2/10 = 1/5 compared to (a) of FIG.
[0070]
FIG. 11C shows an example of assignment for each low level (conventional). here,
Planning conditions: latest delivery, backward
(1) to (6) show the situation when assigned by. The bill of materials shall be as described in the upper right.
[0071]
Since the latest delivery date is June 10,
・ ▲ 1 ▼ Product Y, 1000 pieces
・ ▲ 2 ▼ Product X, 1000 pieces
・ ▲ 3 ▼ Product Y, 1000 pieces
・ ▲ 4 ▼ Product X, 1000 pieces
Since the number of days becomes the start date, the parts A necessary for manufacturing these products X and Y are arranged in (5) and (6). In this case, from (1) to (4) There is a drawback that 100% of all products X and Y in (2) become an infeasible production plan.
[0072]
FIG. 11D shows an example of a concurrent schedule (the present invention). Here, even if allocation is performed under the same planning conditions (latest delivery date, backward) as in FIG. 11C, as described above, allocation is performed in the order of low-level products and parts used for manufacturing the products (illustrated example). Then (Product Y: 1000 pieces, Product X: 1000 pieces, Parts A: 2000 pieces)
・ ▲ 1 ▼ Product X, 1000 pieces
・ ▲ 2 ▼ Product Y, 1000 pieces
-(3) Parts A. 2000 pieces
It is possible to assign backward from 10 (Saturday) of the delivery date in this order. And the rest
・ ▲ 6 ▼ Product X, 1000 pieces
・ ▲ 5 ▼ Product Y, 1000 pieces
-(4) Parts A. 2000 pieces
With regard to, if it is assigned backwards with 10 (Saturday) as the final date, it will be found that a production plan that is four days behind on Wednesday, June 14 can be drafted. As a result, it is possible to formulate a production plan in which 50% of the products X and Y can be manufactured by the delivery date, which is much larger than when all the products X and Y in FIG. 11C cannot be manufactured by the delivery date. It turns out to be improved.
[0073]
FIG. 12E shows an example of assignment for each low level (conventional). Here, if you assign backwards from the delivery date (10th Saturday) for each low level,
・ ▲ 1 ▼ Product X, 1000 pieces
・ ▲ 2 ▼ Product Y, 1000 pieces
・ ▲ 3 ▼ Product X, 500 pieces
・ ▲ 4 ▼ Product Y, 500 pieces
・ ▲ 5 ▼ Part A, 1000 pieces
・ ▲ 6 ▼ Part A, 1000 pieces
And backward allocation, the number of days becomes the start date,
・ ▲ 7 ▼ 1000 parts A
Becomes the next day (11th) after the delivery date (10th Saturday), and as a result, (1) product X, 1000 pieces and (7) part A, 1000 pieces are infeasible production plans (▲ 1 ▼ Product X, which is a production plan in which 1000 pieces cannot be manufactured by the delivery date).
[0074]
FIG. 12 (f) shows an example of a concurrent schedule (the present invention). Here, even if it is assigned under the same planning conditions as in FIG. 12 (e), as described above, if it is assigned in the order of the low-level product and the parts used for manufacturing the product,
・ ▲ 1 ▼ Product X, 1000 pieces
・ ▲ 2 ▼ Part A, 100 pieces
・ ▲ 3 ▼ Product Y, 1000 pieces
・ ▲ 4 ▼ Part A, 1000 pieces
・ ▲ 5 ▼ Product X, 500 pieces
・ ▲ 6 ▼ Product Y, 500 pieces
・ ▲ 7 ▼ 1000 parts A
In this order, it is possible to assign a backward from 10 (Saturday) of the delivery date, and to make a production plan capable of producing 100% of products X and Y.
[0075]
【The invention's effect】
As described above, according to the present invention, it is possible to reduce wasteful inventory by simultaneously planning a material plan and a resource plan. This
(1) Stock reduction
(2) Reduction of manufacturing lead time
(3) Flexible production plan can be changed
(4) Factory with strict deadline
(5) Reduction of man-hours for creating production plans
Can be achieved.
[Brief description of the drawings]
FIG. 1 is a system configuration diagram of the present invention.
FIG. 2 is a flowchart explaining the operation of the present invention.
FIG. 3 is a detailed operation explanation flowchart (required amount calculation) of the present invention.
FIG. 4 is a flowchart (assignment) for explaining detailed operations of the present invention.
FIG. 5 is an explanatory diagram of the present invention.
FIG. 6 is a diagram for explaining the operation of the present invention (part 1);
FIG. 7 is an operation explanatory diagram (No. 2) of the present invention.
FIG. 8 is an operation explanatory view (No. 3) of the present invention.
FIG. 9 is a diagram for explaining the operation of the present invention (part 4);
FIG. 10 is an explanatory diagram (part 1) of the present invention.
FIG. 11 is an explanatory diagram (part 2) of the present invention.
FIG. 12 is an explanatory diagram (part 3) of the present invention.
[Explanation of symbols]
1: Database
2: Order data database
3: Unarranged database
4: Inventory data day nest
5: Product number database
6: Parts list database
7: Manufacturing plan database
8: Order plan database
10: Memory table
11: Master information table
12: Order information table
13: Plan result table
17: Required amount calculation means
22: Scheduling means
31: Processing means

Claims (4)

Requirement calculating means for calculating the required amount of parts required for production of each product for a plurality of products received an order, and calculating a total value of the calculated required amounts of parts;
First scheduling means for dividing a total value of required parts calculated by the required quantity calculating means into processing units of production equipment ;
Allocates the production of the plurality products having received the order to production equipment, a second scheduling means for assigning the production equipment together production parts divided into processing units of the production equipment by said first scheduling means
Production planning system comprising the. The production planning system according to claim 1, wherein the total value of the required amount of the parts is obtained for the inventory or the remaining inventory and the remaining allocation . A requirement calculation step for calculating a required amount of parts necessary for production of each product for a plurality of products received an order, and calculating a total value of the calculated required amounts of the parts,
A first scheduling step of dividing a total value of required parts calculated by the required quantity calculating means into processing units of production equipment ;
A second scheduling step of allocating the production of the plurality of products received the order to a production facility and allocating the production of parts divided into processing units of the production facility together by the first scheduling means to the production facility ;
Production planning method having . Computer
A requirement calculation step for calculating a required amount of parts necessary for production of each product for a plurality of products received an order, and calculating a total value of the calculated required amounts of the parts,
A first scheduling step of dividing a total value of required parts calculated by the required quantity calculating means into processing units of production equipment;
A scheduling step of allocating the production of the plurality of products received the order to a production facility, and allocating the production of parts divided into processing units of the production facility together by the first scheduling means to the production facility ;
A computer-readable recording medium having recorded thereon a program for causing it to function.

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