JP5003135B2 - Summary order issuing method and issuing system - Google Patents

Description

  The present invention relates to a supply chain in a company, in a group company, or in a company collaboration, between a company and a company, between a factory (manufacturing base) and a factory (manufacturing base), between a work center and a work center. The present invention relates to a method and system for issuing a collective order from downstream to upstream in a supply chain between processes.

  FIG. 23 is a conceptual diagram showing the relationship between a general flow of request information and a manufacturing flow (a flow of goods) in a supply chain. As shown in FIG. 23, when a production request order 42 is issued from the order request source 41, a production plan 43 is first created in a downstream process (work area, production base), and when the production plan is compiled in the downstream process, the upstream process A production request order 44 is issued in order to create a production plan 45 at (work center, production base). Based on the manufacturing request order 42 from the downstream process, a manufacturing plan 45 is created and manufactured in the upstream process. As a result, a request information flow 46 is formed. Further, when a product (intermediate product) is produced in the upstream process, the product (intermediate product) is supplied as an input item to the downstream process, and the product is obtained by acquiring the product (intermediate product) in the downstream process. As a result, a manufacturing flow (material flow) 47 is formed.

  However, with the conventional production / manufacturing plan creation system, manufacturing requests between factories (manufacturing bases) and factories (manufacturing bases) in the above supply chain, between work centers and work centers, and between processes, Without considering each other's situation, as shown in Fig. 24, even if the content is the same, it will be different items depending on the packaging, label, etc., so it is summarized in the filling process (filler) and packaging process in the downstream process As a result, it is impossible to produce a finished product. Therefore, there is a demand for intermediate products, parts, materials, etc. required in the downstream process in order to manufacture a finished product (oolong tea can in the illustrated example) 56 in the downstream process. Issuing as is to the upstream process in the form of work center order 51, and in the upstream process, a production plan is made based on the issued work center order 51. For example, in the first upstream tank, product (intermediate product / part / material) 52 In the second upstream tank, products (intermediate products / parts / materials) 53 are manufactured and supplied to the mixing tank, and in the mixing tank, mixed products (intermediate products / parts / materials) 54 are manufactured and used in the downstream process. In the downstream process where the product 55 is supplied and filling (filler) / packaging is performed, the finished product 56 is manufactured based on the supplied product 55. Such a flow was the same even with different PET bottles. Such a conventional technique can be found in, for example, Patent Document 1.

  In the processing and assembly industry, conventionally, only raw materials have been created and issued by upstream companies after planning materials using an MRP (Manufacturing Resource Planning) system between companies. The technology to do is known. However, when not using an MRP system for planning raw materials or when using intermediate products, the upstream process inputs the manufacturing plan (order) received from the downstream process and combines the manufacturing plan (order) at the own factory / process. In other words, after the production plan was adjusted and produced, the product was divided and delivered according to the original request to meet the request of the requester. Furthermore, the adjustment of the production plan was made after confirming whether it was possible to deliver in bulk while contacting the requester.

As another conventional technique, a product described in a plurality of orders has the same process procedure, the delivery date is the same, and the lead time of each process is the same. The technology to create is known. Such a conventional technique can be found in, for example, Patent Document 2.
Japanese Patent Laid-Open No. 10-31703 JP-A-6-259436

  With the diversification of the market and the shortening of the product cycle, companies are forced to produce a variety of products in small quantities. Under such circumstances, the above-described conventional production / manufacturing plan creation system increases the load of the upstream planning work, and takes extra man-hours to exchange data between the upstream and downstream for adjustment. Since the efficiency of the entire supply chain is poor and the lead time of the product is affected, it becomes a problem to realize optimization of the entire manufacturing system.

  In addition, in a production system that produces multiple items by hybrid (mixing), an intermediate product produced in an upstream process / work area, used to produce multiple types of products (final products) produced in a downstream process / work area, When the parts are the same, it may be efficient to collectively manufacture intermediate products or parts manufactured in the upstream process. In order to manufacture collectively in the upstream, it is desirable that orders from the downstream to the upstream (work center order) are appropriately issued in advance.

  On the other hand, since orders have many modes such as delivery date and size (quantity), it takes a lot of effort for the planner to decide which order and which order should be combined to generate a new order. Therefore, if it is possible to create a summary of orders, it has been desired to realize it automatically and in consideration of the above-described factors.

  Therefore, the object of the present invention is to collect the work order from the downstream process to the upstream process, the capacity (capacity) of the upstream equipment (tank, etc.), the efficiency in batch production, and the tolerance for maintaining the product quality. In consideration of constraints such as lifetime, it is possible to issue an efficient summary order.

The present invention, upon issuing a work center order from the downstream process to the upstream process, when the material to be produced separately in downstream processes is neighboring a and the same contents item, downstream process in order to produce together the contents in an upstream process The order is issued. Specifically, a collective order is issued based on any one of the following (1) to (3).
(1) Collect orders related to multiple items based on the capacity (capacity) of the equipment.
(2) Summarize orders related to multiple items based on the maximum permissible lifetime (maximum possible storage period for content items required from the hygiene aspect).
(3) Summarize orders related to a plurality of items according to the number of order summaries.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing efficiency in an upstream process (content process) can be improved, and productivity can be improved. Moreover, when issuing a work order, it is possible to reduce the labor of the plan creator and increase the efficiency of the planning work.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a functional block diagram showing an operating environment surrounding a summary order issuing system according to an embodiment of the present invention. In FIG. 1, the head office planning system 100 passes the order 102 stored in the table as shown in FIGS. 2A and 2B to the manufacturing plan creation unit 204 of the packaging (line) process planning system 200 via the interface 202. As the order 102, both all request data (order) shown in FIG. 2 (a) and difference request data (order) shown in FIG. 2 (b) are considered.

  Upon receiving the order 102 from the head office planning system 100 via the interface 202, the manufacturing plan creation unit 204 creates a manufacturing plan with reference to various masters T55 (which will be described later). When the production plan creation is completed, it is stored in the table T53 as a firm plan, and at the same time, a plan firm notification is issued by the production plan creating unit 204 to the summary order issuing system 210 according to the present invention. Further, the instruction data is created and stored in the instruction data table T52 when the plan is confirmed. The confirmed plan stored in the table T53 is sent to the plan response table 104 of the head office planning system 100 via the interface 202 and stored.

  The summary order issuing system 210 acquires the parameters set in the table T51, creates a summary order that matches various conditions and constraints defined in the parameters, and stores the summary orders in the order data (summary order) table T54. The data is temporarily stored and output to the instruction data table T52 to rewrite the instruction data table T52 in a collective order. The instruction data rewritten by the collective order is output as (consolidated) order 302 to the content manufacturing process planning system 300 via the interface 202 and the network 50. The content manufacturing process planning system 300 receives the (summary) order 302 sent via the interface 202 and the network 50 and inputs it to the process management unit 304. The process management unit 304 performs process management on the received (summary) order. , (Summary) Manufacture products based on orders.

FIG. 3 is a block diagram showing the configuration of the summary order issuing system according to the embodiment of the present invention. In FIG. 3, the setting parameter acquisition unit 211 receives a plan confirmation notification based on the completion of the manufacturing plan of the manufacturing plan creation unit 204 shown in FIG. 1 and acquires the setting parameters defined in the data table T51. . In addition, the setting parameters include the following conditions and restrictions.
(1) Do you order together? (2) Do you collect by line? (3) Do you allow overlapping of tank occupancy (use) time? (4) Do you put together only (number of orders) in the neighborhood? (5) Allowable lifetime (6) Conditions for excluding all large orders (7) Conditions for excluding integer batch (close to) orders (8) Conditions for maximum capacity (9) Integer batch FIG. 4 shows the data structure of the data table T53. As shown in the fixed plan table T53 in FIG. 4, the production quantity, the production start date, the production start time, the production end date, the production end time, the operation time, and the switching time for the item (identified by the item code) manufactured for each production line. Data such as the contents item (equivalent to the tank manufacturing item) code and the number of batches are included.

  The summary order availability determination unit 212 determines the setting parameter (1) and determines whether to execute the summary order. Here, when the collective order is not performed according to the setting parameter (1), the instruction data stored in the data table T52 is output as the order 302 to the content manufacturing process planning system 300 via the interface 202 and the network 50 as usual. FIG. 5 shows the data structure of the instruction data stored in the data table T52.

The item correspondence order grouping means 213 obtains an item (intermediate product) from information related to the item (intermediate product) stored in various masters T55 (see FIGS. 6 to 9) and the confirmed plan data stored in the table T53. The information related to is acquired, and orders are grouped for each item (intermediate product). In this case, a premise of the present summarized order issuance system, material to produce separately in downstream process to confirm that the neighboring a (manufactured close) and the same contents item, the setting parameter (2), (3 ) Is considered.

  The data structures of various masters stored in the data table T55 are shown in FIGS. In other words, FIG. 6 shows the item master, the item and the content item are defined, and FIG. 7 shows the process master, which defines the item and the previous process connected to the item. FIG. 8 shows the equipment capacity master, which defines the items and the production amount of the tank, etc. FIG. 9 shows the operation rate master, and defines the operation rates of the items and equipment. .

  The neighboring order designation number grouping means 214, when the condition setting of the setting parameter (4) has a designation of “combining only by the (order) summary number in the neighborhood”, the designated number (number is the work Group based on a rule of thumb of a member), for example, an integer from 3 to 5. If grouping is possible, the grouping result is output to the summary order issuing means 222. The “neighboring order” means that the items in a plurality of orders are the same and the production start time is close.

  The required quantity calculation means 215 within the group is required for each input item (intermediate product) grouped by the item corresponding order grouping means 213 when the grouping by the neighboring order specified number grouping means 214 is impossible. Is calculated. That is, data necessary as input items (intermediate products) is collected for each item from the confirmed plan data in the table T53, and added by a calculation function (not shown) provided in the system to obtain a necessary amount.

  The item-corresponding tank capacity acquisition means 216 acquires the tank capacity (batch size) corresponding to each input item based on the facility capacity information (see FIG. 8) stored in the various masters T55. That is, since each batch size is set for manufacturing in batch, each batch size (tank capacity) is acquired from the batch size.

  The required amount / tank capacity comparing means 217 is an arithmetic operation that this system has the required amount calculated by the in-group item corresponding requirement calculating means 215 and the tank capacity (batch size) acquired by the item corresponding tank capacity acquiring means 216. If the comparison is made by function (not shown) and “Exclude multiple batches (large order)” is specified in the condition setting of the setting parameter (6) above, the required amount of order input is larger than the tank capacity. Exclude orders that In other words, the last order to be added that is the target of addition of the required amount is excluded from the targets of the collective orders.

The plan start / end time acquisition means 218 acquires the start / end time of each plan developed in the fixed plan data stored in the data table T53.
The maximum capacity summarization grouping means 219, if there is a designation of “summarize within the maximum capacity” in the condition setting of the setting parameter (8), the total input item required quantity is within the capacity of the tank (batch size), and In consideration of the constraint condition of “bundling the allowable lifetime as a constraint condition” in the setting of the setting parameter (5), the total time required for product manufacture is sequentially divided and grouped within the maximum allowable lifetime of the content item. . If grouping is possible within the maximum allowable lifetime, the grouping result is output to the summary order issuing means 222.

  The grouping means 220 within the integer batch is within the maximum allowable lifetime in consideration of the setting of the setting parameter (5) when the grouping by the grouping means 219 within the maximum capacity is impossible, and the above setting In consideration of the designation of “collect only in integer batches” in the condition setting of parameter (7), the sum of the content items is grouped by sequentially dividing the sum of the content items by an integer multiple of the tank capacity. If grouping is possible within the maximum allowable lifetime and close to an integral multiple of the tank capacity, the grouping result is output to the summary order issuing means 222.

  The grouping means 221 within the maximum permissible lifetime sets the condition setting of the setting parameter (7) considered by the integer batch grouping means 220 when the grouping by the integer batch grouping means 220 is impossible. Excluded, grouping is performed in consideration of only the constraint condition “collect the allowable lifetime as a constraint condition” in the condition setting of the setting parameter (5).

  The summary order issuing unit 222 is grouped by the neighboring order designation number grouping unit 214, the maximum capacity grouping unit 219, the integer batch grouping unit 220, and the maximum allowable lifetime grouping unit 221. As for the results, from several target orders, the earliest necessary time is set as the delivery date, and the total production quantity is summarized as the production quantity and the order is issued.

  As described above, the summary order issuing system 210 issues a summary order to the data table T54, and further sends a summary order for rewriting from the data table T54 to the data table T52. In the data table T52, the instruction data is rewritten based on the issued summary order and output to the interface (see the interface 202 in FIG. 1).

FIG. 10 is a flowchart for explaining the operation of the summary order issuing system according to the embodiment of the present invention. In FIG. 10, when the summary order issuing system according to the embodiment of the present invention receives a plan confirmation notification from the manufacturing plan creation unit 204 shown in FIG. 1, in step 21, the setting parameter defined in the data table T51 is acquired. In the data table T51, the following conditions and constraints are defined as setting parameters. That is,
(1) Do you order together? (2) Do you collect by line? (3) Do you allow overlapping of tank occupancy (use) time? (4) Do you put together only (number of orders) in the neighborhood? (5) Allowable lifetime (6) Conditions for excluding all large orders (7) Conditions for excluding integer batch (close to) orders (8) Conditions for maximum capacity (9) Integer batch In step 22, the setting parameter (1) is determined. When the collective order is not performed, the instruction data stored in the data table T52 is output to the interface (see the interface 202 in FIG. 1) as usual. Then, when performing the collective order, the process proceeds to step 23, and based on the information related to the items stored in the various masters T55 (see FIGS. 6 to 9) and the information stored in the data table T53 in step 23. , Acquire input items (intermediate products) and group orders by the acquired input items (intermediate products). Next, in step 24, adjacent orders are grouped by being sequentially separated by a specified number, for example, any integer of 3 to 5. If grouping is possible with the number specified here, the process proceeds to step 31. On the other hand, if the specified number cannot be grouped, the process proceeds to step 25. In step 25, based on the equipment capability information stored in various masters T55 (see FIG. 8) and the information stored in the data table T53, the required amount for each input item (intermediate product) in each grouping is calculated. While calculating, the capacity (batch size) corresponding to each input item is acquired. Next, at step 26, when there is a designation "exclude multiple batches (large order)" set by the setting parameter (6), orders whose order input required amount is larger than the tank capacity are excluded.

In step 27, the start / end times of each plan are acquired based on the confirmed plan data stored in the data table T53. If there is a set "summarized in the maximum capacity" specified in step 28 the setting parameter (8) is then within the capacity of the tank the total input material requirements (batch size), and the setting parameters ( The total time required for product manufacturing is grouped by sequentially dividing within the maximum permissible lifetime of the content item under the constraint condition of “bundling permissible lifetime as a constraint” set in 5). If grouping is possible within the maximum allowable lifetime, the process proceeds to step 31. On the other hand, if grouping is not possible within the maximum allowable lifetime, the process proceeds to step 29. In step 29, when there is a designation of “collect only in integer batches” set in the setting parameter (7), the total of the content items is sequentially separated in the same procedure as in step 28, close to an integral multiple of the tank capacity. Group. If grouping is possible within the maximum allowable lifetime and close to an integral multiple of the tank capacity, the process proceeds to step 31. On the other hand, if grouping is not possible within the maximum allowable lifetime and close to an integral multiple of the tank capacity, the process proceeds to step 30. In step 30, grouping is performed in the same procedure as in step 29 without limitation of integer batches. Then, the process proceeds to step 31. In step 31, the earliest necessary time is set as the delivery date and the total production amount is issued as the production quantity from several target orders, and the order is issued. The summary order is sent to the data table T54, and is sent to the data table T52 as a summary order for rewriting the instruction data. In the data table T52, the instruction data is rewritten by the collective order and then output to the interface (see the interface 202 in FIG. 1).

  FIG. 11 to FIG. 22 are diagrams for specifically explaining a method of creating a collective order that is issued by the collective order issuing system according to the embodiment of the present invention using the above-described setting parameters. FIG. 11 shows an example in which orders are grouped by line using the same setting parameter (2) when the ordering is performed using the setting parameter (1). Before entering the description of FIG. 11, in general, in a method of supplying a content item (intermediate product) from a tank to a line, it may or may not be possible to supply to multiple lines at the same time due to piping restrictions. I want to be. In FIG. 11A, when contents items cannot be supplied simultaneously to a plurality of lines, it is meaningless to group orders across the lines, so the orders are grouped by line. This case is dealt with by designating “combined by line” in the setting parameter (2). In the first line shown in FIG. 11A, product A: 9800 and product C: 3000 are grouped together, product D: 2700, product C: 3000, product K: 3200, and grouped together. : 1700 ... in one, and in the second line, product B: 6400, product E: 2500, product F: 3800, in one, product E: 6500, product G: 2800, product B : Shows that you can combine them with 8000. The numbers represent production quantities, and the unit is liters.

  Next, in FIG. 11 (b), when content items can be supplied simultaneously to a plurality of lines, they can be grouped across the lines, so there is no need to group by line. In this case, this can be dealt with by not specifying “Summarize by line” in the setting parameter (2). In FIG. 11 (b), the product A: 9800, product B: 6400, product C: 3000 are combined into one product A: 2500, product D: 2700 across the first line and the second line. It is shown that the product E: 6500, product C: 3000, product K: 3200, product G: 2800, and product H: 1700, product B: 8000. The numbers represent production quantities, and the unit is liters.

  In FIG. 11 (c), content items cannot be supplied to multiple lines at the same time. However, when supplying to multiple lines in a time-division manner by switching pipes, specify “Summarize by line” in the setting parameter (2) above. Instead, it can be handled by putting it across the lines. In FIG. 11 (c), the first line and the second line are grouped together in a time series and across the lines as product A: 9800, product E: 2500, product F: 3800, and product C: 3000. , Product K: 3200, product G: 2800, and product H: 1700, product B: 8000. The numbers represent production quantities, and the unit is liters.

  In FIG. 12, when the overlap of tank occupancy (use) time is allowed by the setting parameter (3) described above, the time occupancy of tank occupancy (use) by a production plan in a plurality of lines is allowed and the orders are summarized. An example is shown. Before entering the description of FIG. 12, it is normal that there are a plurality of tanks. However, assuming that only one specific tank can be used for a specific line, if there is only one tank, Use) Note that time cannot be overlapped, so it must be differentiated according to the setting. In FIG. 12, the first line and the first tank, and the second line and the second tank are set so as to have a specific relationship. ) Is allowed to be issued over time. That is, in the first line, product A: 9800 and product C: 3000 are combined into one, corresponding to the production plan of item M in the first tank (A + C: 12800), and over time. In the second line, product B: 6400, product E: 2500, product F: 3800 are combined into one and correspond to the production plan for item M in the second tank (B + E + F: 12700). In the first line, product D: 2700, product C: 3000, product K: 3200 are combined into one, and the production plan for item M in the first tank (D + C + K: 8900) is used. In the second line, product E: 6500, product G: 2800, product B: 8000 are combined into one, and the production plan for item M in the second tank ( E + G + B: 17300). For the product H and the subsequent products in the first line, no production plan is displayed here.

  FIG. 13 shows an example in which orders are combined by a production plan on a single line when the allowable lifetime is set as a limiting condition by the setting parameter (5) and the overlapping of the tank occupation (use) time is not allowed. ing. In FIG. 13, it is assumed that the capacity (batch size) of the tank for producing the intermediate item M is 20000 liters, and the period in which the intermediate item M can be stored in the tank in consideration of the hygiene aspect, that is, the maximum allowable survival A period is set. In FIG. 13, when there is only one tank, it is not allowed to overlap the occupied (use) time of the tank, so even if the intermediate item M to be manufactured is within the maximum allowable lifetime, A batch order exceeding the capacity (batch size) cannot be issued, and the orders are collected within the tank capacity (batch size). In the figure, if it is assumed that products A: 9800, product B: 6400, product C: 3000, and product E: 2500 are ordered, products C and E satisfy the condition that they are within the allowable lifetime even if products C and E are included. If E is added, the size will be oversized, and the order will be collected according to the production plan (A + B: 16200) of the item M in the tank. In addition, if it is assumed that the order is made up of product C: 4400, product E: 3800, product D: 4200, product F: 5400, product G: 3000, the product G satisfies the condition that it is within the allowable lifetime. If G is added, the size will be oversized, so the order will be put together according to the production plan for the item M in the tank (C + E + D + F: 17800). In this case, as shown in FIG. 6, in the case where there are a plurality of tanks and the occupancy (use) time of the tanks is allowed, the order is summarized by the production plan (A + B + E: 20000) of the item M in the first tank. In the second tank, the orders are collected according to the production plan for item M (C + D + F + G: 17000). However, even if the product H (not shown) is inserted, the upper limit of the size is not exceeded. However, if the product H is extended until the end time of the product H, the allowable lifetime of the second tank is exceeded, so the product H cannot be inserted.

  FIG. 14 shows an example of summarizing orders in the case where it is selected that the above-mentioned setting parameter (4) is to be grouped by the number of (order) groups in the vicinity. Before entering the description of FIG. 14, in the downstream process (line process) in which filling and packaging operations are generally performed, there is no guarantee that a tank for producing an intermediate product in the upstream process necessarily exists. It should be noted that it is necessary to provide support for providing users with a method for creating simple summary orders that can be used in various situations. Accordingly, in FIG. 14, the number of uniforms is determined uniformly based on the long experience of workers, and the orders are summarized based on the number of totals. In addition, about how to determine the number of summaries, it is assumed that the start time is counted in order from the earliest without skipping. If the start times are the same, the completion times are set in ascending order. In FIG. 14A, the number of summaries is designated for each line and summarized. That is, the number of summaries is 3, and from the first line with the fast start time, product A: 9800, product C: 3000, product D: 2700, and product C: 3000, product K: 3200, product H : Combined with 1700. On the other hand, in the second line, product B: 6400, product E: 2500, product F: 3800 are combined into one, and product E: 6500, product G: 2800, product B: 8000 are combined into one.

  In FIG. 14B, the number of (order) summaries is specified at the same time for a plurality of lines without being classified by line. In this case, it is assumed that the start times are collected in ascending order. The number of summaries is 3, in order from the earliest start time, product A: 9800, product B: 8000, product C: 3000, and one product E: 2500, product D: 2700, product F: 3800 Summarize, product E: 6500, product C: 3000, product K: 3200, and product G: 2800, product H: 1700, product B: 8000.

  FIG. 15 shows an example of summarizing orders in the case where it is selected that the allowable lifetime is summarized as a constraint condition by the setting parameter (5). Before entering the explanation of Fig. 15, there may be a strict requirement for the period from production (intermediate product) production (start of production) / intake to completion of consumption / dispensation for certain reasons due to hygiene and quality reasons. Note that this requirement must be considered as a constraint when manufacturing together. In addition, when producing a product (intermediate product) in batches, the allowable lifetime is the time in one batch. FIG. 15 shows an example in which orders are collected using the allowable lifetime when the occupied (used) times of the tanks do not overlap as a constraint. The target orders to be collected are the orders from the start time of the earliest start order to the end within the allowable lifetime. In FIG. 15, the start time of the allowable lifetime is the order start time, and it is assumed that the product (intermediate product) is supplied by a single tank and the product is supplied to a plurality of lines. In other words, regarding the production plan for one tank, if product A: 9800, product C: 3000, product D: 2700 are manufactured in the first line, and product E: 2500 is manufactured in the second line If the production plan is extended to the production completion time of the product D, the maximum allowable lifetime of the intermediate item M will be exceeded, so the product D cannot be put together as an order, and the production plan for the item M (A + C + E) In the first line, product A: 9800, product C: 3000 and in the second line, product E: 2500 are combined. Also, if product D: 2700, product C: 3000, product K: 3200, product H: 1700 are manufactured in the first line, and product G: 2800 is manufactured in the second line, intermediate item M Since these products can be manufactured within the maximum allowable lifetime, product D: 2700, product C: 3000, product K: 3200, product in the first line as the production plan (D + C + G + K + H) of item M in one tank H: 1700 and product G: 2800 in the second line.

  FIG. 16 shows another example of summarizing orders in the case where it is selected that the allowable lifetime is constrained as a constraint condition by the setting parameter (5). FIG. 16 shows an example in which orders are collected using the allowable lifetime when the occupied (used) times of the tanks overlap as a constraint. As in FIG. 15, the target orders to be collected are the orders from the start time of the earliest start order to the end within the allowable lifetime. In FIG. 16, it is assumed that the start time of the allowable lifetime is the start time of the order, and a plurality of tanks for manufacturing products (intermediate products) are prepared and products are supplied to a plurality of lines. That is, regarding the production plan in the first tank, product A: 9800, product C: 3000, product D: 2700 are manufactured in the first line, and product B: 6400, product E: 2500, in the second line. When product F: 3800 is manufactured, if the production plan is extended to the completion time of product D, the maximum allowable lifetime of intermediate item M will be exceeded, so product D cannot be grouped as an order. As the production plan of item M in the first tank (A + B + C + E + F), product A: 9800, product C: 3000 in the first line, product B: 6400, product E: 2500, product F: 3800 in the second line And put them together. Also, regarding the production plan for the second tank, where the tank occupancy (use) time overlaps, the product D: 2700, product C: 3000, product K: 3200, product H: 1700 are manufactured in the first line. If product E: 6500 and product G: 2800 are manufactured in line 2, these products can be manufactured within the maximum allowable lifetime of intermediate item M, but if the production plan is extended to the completion time of product H Since the maximum allowable lifetime of the intermediate item M will be exceeded, the product H cannot be put together as an order, and the product D on the first line as the production plan (D + E + C + K + G) of the item M in the second tank: 2700, product C: 3000, product K: 3200, and E: 6500 and product G: 2800 in the second line.

  FIG. 17 shows still another example of summarizing orders in the case where it is selected that the allowable lifetime is constrained as a constraint condition according to the setting parameter (5). FIG. 17 shows an example in which orders are collected using the allowable lifetime when the occupied (used) times of the tanks do not overlap as a constraint. In FIG. 17, the target orders to be collected are the orders from the start time of the last batch of the large size order to the end within the allowable lifetime. That is, in FIG. 17, the start time of the allowable lifetime is the start time of the last batch of the large order, and the product (intermediate product) is supplied to one line with only one tank for manufacturing the product (intermediate product). Shall. In other words, for a production plan in one tank, product A: 9800 is produced in multiple batches (batch 1 to 4) on one line, and product D: 2700 from the production start time of the last batch (batch 5). If product C: 300, product H: 500, and product B: 6400 are manufactured, if the production plan is extended to the completion time of product B, the maximum allowable lifetime of intermediate item M will be exceeded. B cannot be grouped as an order, but as a production plan for item M (A + D + C + E), batch A for product A, product D: 2700, product C: 300, product H: 500 in one line .

  FIG. 18 shows an example in which orders are collected when a large order (order close to or exceeding the maximum capacity of the tank) is selected by the setting parameter (6) as a condition. FIG. 18A illustrates a problem when a large order (or an order close to one batch) is not excluded. That is, there is a problem that batch switching is performed in an order that does not originally require batch switching (in the example illustrated, an order for manufacturing the product B). In FIG. 18 (a), it is assumed that 4 is set as the number of summaries, and since the number of summaries is less than four, manufacturing is performed to manufacture product A: 26000, product B: 8000, product C: 3000, and product B: 8000. Although it should be possible to plan, batch switching is encountered in the process of manufacturing product B: 8000. That is, in FIG. 18A, when the maximum capacity of the tank is 10,000 liters and the minimum capacity of the tank is 3000 liters, the production plan for batches 1 to 4 in the production plan (A + B + C + B) of the item M in the tank Then, it cannot be gathered up and bites into batch 5. Therefore, batch switching must be performed in the process of manufacturing the product B: 8000.

  In order to avoid this, as shown in FIG. 18 (b), the problem is solved by setting the condition to exclude large orders (orders close to or exceeding the maximum capacity of the tank). That is, in the order series as shown in FIG. 18B, product A: 26000, product B: 8000, product C: 3000, product B: 8000, product D: 2700, product K: 3100, product H: 1200 In the case of manufacturing, under the assumption that multiple tanks can be used to increase the tank occupation (use) time, products A: 26000 and Product B: 8000, which are large orders, are excluded from the collection target from the beginning. The production of product C: 3000, product D: 2700, product K: 3100, and product H: 1200 are combined into one order. That is, with respect to the production plan in the first tank, the production plan (C + D + K + H) of the item M is established and manufactured. The product A and the product B are individually planned and manufactured. An order close to the maximum capacity of the tank is identified by the following method. That is, whether the individual size is (a) standard capacity × select (90%, or, 80%, or, 70%) ≦ individual size ≦ maximum capacity, or (b) (maximum capacity−minimum amount that can be manufactured) ≦ Individual size ≦ Maximum capacity.

  FIG. 18 (c) shows the following order series: product A: 26000, product B: 8000, product C: 3000 under the assumption that the tank occupation (use) time cannot be overlapped using a single tank. , Product B: 8000, Product D: 2700, Product K: 3100, Product H: 1200, Product E: 5000, Product D: 2700, Product K: 3100, Product H: 1200, Product E: Combine 5000 productions into one order. That is, the manufacturing plan (D + K + H + E) for the item M is made in a single tank.

  FIG. 19 shows an example in which the orders are collected when the setting parameter (7) is selected on the condition that only integer batch (close) orders are excluded. An integer batch (close to) order is referred to as an integer batch order when the size of the fraction batch obtained as a result of the batch calculation satisfies the following conditions. That is, whether the fraction size is (a) standard capacity × select (90%, or, 80%, or, 70%) ≦ fractional size ≦ maximum capacity, or (b) (maximum capacity−minimum amount that can be manufactured) ≦ This is the case where fraction size ≦ maximum capacity. In FIG. 19, if it is assumed that the order of integer batches (near) is not removed, batch switching is performed in an order that does not originally require batch switching (order for manufacturing the product B in the illustrated example). There's a problem. In FIG. 19, it is assumed that the maximum capacity of the tank is 11000 liters, the standard batch size is 10000 liters, and the minimum capacity of the tank is 3000 liters. In the order series shown in FIG. 19, product A: 25000, product B: 8000, product C: 3000, product B: 8000, product D: 2700, product K: 3100, product H: 1200, product E: 5000 are manufactured. In this case, the integer batch order defined above corresponds to the order of product B for the integer batch order. That is, the product B: 8000 has an integer batch order because 11000−3000 = 8000 ≦ fractional size ≦ 11000. On the other hand, since the product A: 25000 has a fraction = 5000, 11000−3000 = 8000 ≦ fraction size ≦ 11000 does not hold, and therefore, it does not become an integer batch order. Therefore, in FIG. 19, the orders are collected except for the product B which is an integer batch order.

  FIG. 20 shows an example of summarizing orders in the case where selection is made under the condition that the tanks are grouped up to the maximum capacity according to the setting parameter (8). It is obvious that large orders are excluded in this case. In FIG. 20, the maximum capacity of the tank is 10,000 liters and the minimum capacity of the tank is 3000 liters. FIG. 20A illustrates a problem when the large size order is not removed. That is, there is a problem that batch switching is performed in an order that does not originally require batch switching (in the example illustrated, an order for manufacturing the product B). In FIG. 20 (a), it is assumed that 4 is set as the number of summaries, and since the number of summaries is less than four, manufacturing is performed to manufacture product A: 26000, product B: 8000, product C: 3000, and product B: 8000. Although it should be possible to plan, batch switching is encountered in the process of manufacturing product B: 8000. That is, in FIG. 20A, the production plan (A + B + C + B) of the item M in the tank cannot be gathered up by the production plans from the batches 1 to 4, and bites into the batch 5. Therefore, batch switching must be performed in the process of manufacturing the product B: 8000.

  In order to avoid this, as shown in FIG. 20 (b), the problem is solved by setting a condition that the large-size order is excluded and the tanks are combined up to the maximum capacity. That is, in the order series as shown in FIG. 20B, product A: 26000, product B: 8000, product C: 3000, product B: 8000, product D: 2700, product K: 3100, product H: 1200 When manufacturing, under the assumption that multiple tanks can be used to occupy (use) the tank, the large product A: 26000 and product B: 8000 are excluded from the collection target from the beginning. The production of product C: 3000, product D: 2700, product K: 3100, and product H: 1200 are combined into one order. That is, with respect to the production plan in the first tank, the production plan (C + D + K + H) of the item M is established and manufactured. The product A and the product B are individually planned and manufactured. Large size orders are identified by the following method. That is, whether the individual size is (a) standard capacity × select (90%, or, 80%, or, 70%) ≦ individual size ≦ maximum capacity, or (b) (maximum capacity−minimum amount that can be manufactured) ≦ Individual size ≦ Maximum capacity.

  FIG. 20 (c) shows the following order series: product A: 26000, product B: 8000, product C: 3000 under the assumption that the tank occupation (use) time cannot be overlapped using a single tank. , Product B: 8000, Product D: 2700, Product K: 3100, Product H: 1200, Product E: 5000, when manufacturing Product D: 2700, Product K: 3100, Product H: 1200 Grouped into two orders. In consideration of manufacturing with product E: 5000, the condition is cleared within 4 batches, but the maximum capacity of the tank is exceeded, so product E: 5000 cannot be added. That is, the manufacturing plan (D + K + H) of the item M is made and manufactured in a single tank.

  FIG. 21 shows an example of summarizing orders when selection is made under the condition that they are grouped in integer batches according to the setting parameter (9). FIG. 21 shows an example in which a small order is added to a fraction of a large order and the sizes are close to one batch. Here, there are the following two examples of patterns that can be combined into one batch with a fraction of the large order and some of the small orders. That is, there are (a) a pattern that can be grouped in a start batch of a large size order, and (b) a pattern that can be grouped in an end batch of a large size order. Assuming that the maximum capacity of the tank is 11000 liters, the standard batch size is 10000 liters, and the minimum capacity of the tank is 3000 liters, the order shown in FIG. 21, ie, product A: 34000, product C: 3000, product D: 2700, product F : When manufacturing 4000, first focus on product A: 34000, manufacture product A from batch 1 to batch 3 in standard batch size (ie, batch 3 up to 10000 liters x 3 batches = 30000 liters), product A The remaining 4000 liters will be produced in the last batch 4. Therefore, the start time (LOLBST) of batch 4 (that is, the final batch of the large order) is set, and the tank occupation time corresponding to the fraction allocated to the large order is AT, the end time (LOET) of the large order, and the maximum allowable survival of item M Assuming the completion time (SOET) of the last small order in the period, the duration of the last batch = (occupation time AT for fractions allocated to large order bundling + occupation time until completion of small order) <allowable duration = last The completion time of the small order (SOET)-the start time (LOLBST) of the final batch of the large order, and the start time (LOLBST) of the final batch of the large order ≤ end time of the large order (LOET)-((LOET-large order Start time) / number of batches)-maximum allowable interruption period of large order, and occupation time until completion of small size = completion time of last small order (SOET)-end time of large order (LOET) If satisfied, large size Can be gathered in the end batch of the reader. In addition, although the example gathered by the pattern (b) was demonstrated above, the same applies to the pattern (a).

  FIG. 22 shows another example of summarizing orders in the case where selection is made on the condition that only the integer batches are grouped according to the setting parameter (9). FIG. 22 shows an example in which a plurality of small orders are collected in a size close to one batch. If the maximum capacity of the tank is 10000 liters and the minimum capacity of the tank is 3000 liters, the order shown in FIG. 22 (a), that is, product A: 26000, product B: 8000, product C: 3000, product B: 8000, product D: 2700, product K: 3100, product H: 1200, product E: 5000, the product A: 26000 and product B: 8000, which are large orders (or orders close to one batch), are excluded, and the rest Focus on the small order.

  As shown in FIG. 22 (b), the product A: 26000 and the product B: 8000, which are large orders, are assumed from the beginning under the assumption that the tank occupation (use) time can be overlapped using a plurality of tanks. The products are excluded from the collection target, and the remaining small orders, product C: 3000, product D: 2700, product K: 3100, and product H: 1200, are combined into one order so as to be manufactured in one batch. That is, with respect to the production plan in the first tank, the production plan (C + D + K + H) of the item M is established and manufactured. The product A and the product B are individually planned and manufactured.

  On the other hand, as shown in FIG. 22 (c), under the assumption that the tank occupation (use) time cannot be overlapped using a single tank, products A: 26000 and B: 8000, which are large orders. Are manufactured in order, and the product D: 2700, product K: 3100, and product H: 1200 are combined into one order so that small orders are manufactured in one batch. Here, when attention is paid to the product E: 5000, the condition that the number of groups is 4 or less is cleared, but the maximum capacity of the tank is exceeded, so it is not possible to combine them into one order. That is, with respect to the production plan in a single tank, the production plan (D + K + H) of the item M is made and manufactured.

It is a functional block diagram which shows the operating environment surrounding the summary order issue system which concerns on embodiment of this invention. It is a figure which shows the structure of the order table in a head office planning system. It is a figure which shows the structure of the summary order issue system which concerns on embodiment of this invention. It is a figure which shows the structure of the fixed plan table which concerns on embodiment of this invention. It is a figure which shows the structure of the order data table which concerns on embodiment of this invention. It is a figure which shows the structure of the item master in the various masters concerning embodiment of this invention. It is a figure which shows the structure of the process master in the various masters concerning embodiment of this invention. It is a figure which shows the structure of the equipment capability master in the various masters concerning embodiment of this invention. It is a figure which shows the structure of the operation rate master in the various masters concerning embodiment of this invention. It is a flowchart for demonstrating operation | movement of the summary order issue system which concerns on embodiment of this invention. FIG. 10 is a diagram illustrating an example of collecting orders for each line using the setting parameter (2) when the order is set using the setting parameter (1). It is a figure which shows the example which permits the time overlap of the tank by the manufacturing plan in several lines, and summarizes an order, when the overlap of the tank occupation (use) time is permitted by the setting parameter (3). It is a figure which shows the example which puts together an order by the manufacturing plan in a single line, when the allowable lifetime is made into a constraint condition by setting parameter (5), and the overlap of tank occupation (use) time is not permitted. It is a figure which shows the example which summarizes the order in the case of selecting to summarize by the (order) summary number in the neighborhood by the setting parameter (4). It is a figure which shows the example which summarizes the order at the time of selecting selecting the allowable lifetime as a constraint condition by a setting parameter (5). It is a figure which shows another example which summarizes the order at the time of selecting selecting the allowable lifetime as a constraint condition by setting parameter (5). It is a figure which shows another example which summarizes the order at the time of selecting selecting the allowable lifetime as a constraint condition by setting parameter (5). It is a figure which shows the example which puts together the order at the time of selecting on condition that a large order (order close | similar to or exceeding the maximum capacity of a tank) is excluded by setting parameter (6). It is a figure which shows the example which puts together the order at the time of selecting on condition that only an integer batch order is excluded by setting parameter (7). It is a figure which shows the example which summarizes the order at the time of selecting as a condition to summarize by the setting parameter (8) to a tank maximum capacity. It is a figure which shows the example which summarizes the order at the time of selecting as a condition that it summarizes by an integer batch by a setting parameter (9). It is a figure which shows another example which summarizes the order at the time of selecting on condition that it gathers up with an integer batch by setting parameter (9). It is a conceptual diagram which shows the relationship between the flow of the general request information in a supply chain (supply chain), and the flow of manufacture (flow of goods). It is a figure which shows the prior art example which issues an order from a downstream process to an upstream process, without considering each other's condition.

Explanation of symbols

50 Network 100 Head Office Planning System 102 Order 104 Planning Response 200 Packaging (Line) Process Planning System 202 Interface 204 Manufacturing Plan Creation Unit 210 Integrated Order Issuing System 300 Content Manufacturing Process Planning System 302 (Summary) Order 304 Process Management Unit

Claims (4)

An item master in which the item and the contents of the item are defined, a process master in which the item and the previous process connected to the item are defined, an equipment capacity master in which the production amount of the item and the tank for manufacturing the item is defined, and the item And various master tables consisting of operation rate masters that define the operation rate of the equipment that manufactures the item, and orders from the headquarters planning system, create a production plan with reference to the various masters, and create a production plan Confirmed plan information such as production quantity, production start date, production start time, production end date, production end time, operation time, switching time, content item code, number of batches, etc. And (a) whether to place a collective order, (b) collect by line, (c) allow overlapping tank occupation times, or (d) neighbors ( (E) close to the number of orders, or (e) summarize the allowable lifetime as a constraint, (f) attach conditions excluding all large orders, or (g) integer batch (close to) A setting parameter table for storing information on the conditions and constraints shown in (h) whether the conditions except for the order are attached, (h) grouping within the maximum capacity, or (i) grouping only with the integer batch, When the work center order is issued from the downstream process to the upstream process, and the items separately manufactured in the downstream process are nearby and the same content item, the central processing unit of the information processing apparatus is used to In a batch order issuing method for issuing batch orders from downstream processes in order to bundle and manufacture the contents in the process,
A process in which the central processing unit reads the setting parameter table, determines the setting content of the setting parameter (a), and determines whether to execute a collective order;
On the assumption that the items to be separately manufactured in the downstream process are the same and the same content item and that the collective order is executed in the determination in the process, the central processing unit sets the setting parameter (b) in the setting parameter table. , Confirm that the condition in (c) is set, and further, the central processing unit reads the various master tables and the fixed plan table, information related to the items stored in the various masters, The process of obtaining information related to items stored in the firm plan table and grouping orders for each item,
When the central processing unit reads the setting parameter table and there is a condition setting in the setting parameter (d), the central processing unit sequentially divides and groups adjacent orders by numbers based on empirical rules,
When grouping is not possible in the process of grouping the neighboring orders by the number based on the rule of thumb, the central processing unit is required for each input item grouped in the process of grouping the order for each item. A process of calculating the quantity using the arithmetic function of the central processing unit;
The process in which the central processing unit reads the various master tables and acquires the tank capacity corresponding to the input item based on the facility capacity information stored in the various masters.
The required amount calculated in the process of calculating the required amount for each input item and the tank capacity acquired in the process of acquiring the tank capacity corresponding to the input item are compared using the comparison function of the central processing unit, and further the central processing When the apparatus reads the setting parameter table and there is a condition setting in the setting parameter (f), the central processing unit excludes orders where the required amount of order input is larger than the tank capacity;
The central processing unit reads the fixed plan table and obtains the start / end time of each manufacturing plan stored in the fixed plan table;
When the central processing unit reads the setting parameter table and there is a condition setting in the setting parameter (h), the total input item requirement is within the capacity of the tank, and there is a restriction setting in the setting parameter (e). In this case, the central processing unit sequentially divides and groups the total time required for product manufacture within the maximum allowable lifetime of the content item,
When grouping is impossible in the process of sequentially dividing and grouping within the maximum capacity, the central processing unit reads the setting parameter table, and if there is a setting of a constraint condition in the setting parameter (e), In the case where there is a condition setting in the setting parameter (g) within the maximum allowable lifetime in consideration of the constraint condition, the process of grouping the total of the content items by sequentially dividing the total of the content items by an integral multiple of the tank capacity;
When grouping is not possible in the process of grouping by dividing the total of the content items in order by an integer multiple of the tank capacity, the central processing unit takes into account the process of grouping by dividing the group by the integer multiple of the tank capacity. Removing the set condition of the setting parameter (g) and grouping in consideration of only the constraint condition in the setting parameter (e);
A process of sequentially dividing and grouping the neighboring orders by a number based on an empirical rule, a process of sequentially dividing and grouping the total time required for manufacturing the product within the maximum allowable lifetime of a content item, and a total of the content items The central processing unit is subject to some of the results of grouping by sequentially dividing and grouping near an integral multiple of the tank capacity, and by grouping considering only the constraint conditions in the setting parameter (e). The process of issuing the order as an output by summarizing the total production quantity as the production quantity, with the earliest required time as the delivery date,
A summary order issuing method characterized by including : An item master in which the item and the contents of the item are defined, a process master in which the item and the previous process connected to the item are defined, an equipment capacity master in which the production amount of the item and the tank that manufactures the item is defined, and the item And various master tables consisting of operation rate masters that define the operation rate of the equipment that manufactures the item, and orders from the headquarters planning system, create a production plan with reference to the various masters, and create a production plan Confirmed plan information such as production quantity, production start date, production start time, production end date, production end time, operation time, switching time, content item code, number of batches, etc. And (a) whether to place a collective order, (b) collect by line, (c) allow overlap of tank occupation time, or (d) in the vicinity ( (A) Summarize only by the number of summaries, (e) Summarize the allowable lifetime as a constraint, (f) Add conditions excluding all large orders, or (g) Exclude only integer batch (close) orders A storage device in the information processing apparatus has a setting parameter table for storing information on the conditions and constraints shown in (h) whether to summarize within the maximum capacity or (i) to collect only in an integer batch. When the work center order is issued from the downstream process to the upstream process, if the items to be manufactured separately in the downstream process are the same and the same content item, the contents are determined in the upstream process using the central processing unit of the information processing apparatus. In a batch order issuing system that issues batch orders from downstream processes for batch manufacturing,
A batch order availability determination unit that reads the setting parameter table, determines the setting content of the setting parameter (a), and determines whether to execute the batch order;
The setting parameter (b) of the setting parameter table, on the premise that the items separately manufactured in the downstream process are the same and the same content item, and that the batch order is executed by the determination by the batch order availability determination means, It is confirmed that the condition in (c) is set, and further, the various master tables and the fixed plan table are read out, and the information related to the items stored in the various masters are stored in the fixed plan table. Item-related order grouping means for acquiring information related to the item and grouping orders for each item;
When there is a condition setting in the setting parameter (d) by reading the setting parameter table, neighboring order designation number grouping means for sequentially dividing and grouping neighboring orders by numbers based on empirical rules;
When grouping by the neighboring order designation number grouping means is impossible, the in-group item corresponding requirement calculating means for calculating the required amount for each input item grouped by the item corresponding order grouping means;
Item corresponding tank capacity acquisition means for reading the various master tables and acquiring the tank capacity corresponding to the input items based on the equipment capability information stored in the various masters;
  There is a condition setting in the setting parameter (f) by comparing the required amount calculated by the intra-group item required amount calculating means with the tank capacity acquired by the item corresponding tank capacity acquiring means and reading the setting parameter table. In this case, the required quantity / tank capacity comparing means for excluding orders where the required quantity for order entry is larger than the tank capacity,
Plan start / end time acquisition means for reading the fixed plan table and acquiring the start / end time of each manufacturing plan stored in the fixed plan table;
When the setting parameter table is read and there is a condition setting in the setting parameter (h), the total input item requirement is within the capacity of the tank, and the setting parameter table is read and the constraint setting in the setting parameter (e) is set. If there is, the total time required for manufacturing the product within the maximum allowable lifetime of the content item, grouping means within the maximum capacity that is sequentially divided and grouped,
When grouping by the grouping means within the maximum capacity is impossible, when the setting parameter table is read and the setting of the restriction condition in the setting parameter (e) is set, the maximum allowable survival is considered in consideration of the restriction condition. When the condition parameter is set in the setting parameter (g) by reading out the setting parameter table within the period, the group of integer batches is grouped by sequentially dividing the total of the content items by an integer multiple of the tank capacity. And
When grouping by the grouping means within the integer batch is impossible, the condition setting of the setting parameter (g) considered by the grouping means within the integer batch is excluded, and the constraint condition in the setting parameter (e) Grouping means within the maximum allowable lifetime grouping considering only
For the results of grouping by the neighboring order specified number grouping unit, the maximum capacity grouping unit, the integer batch grouping unit, and the maximum allowable lifetime grouping unit, the target number From this order, the earliest necessary time is set as the delivery date, the total production amount is summarized as the production quantity, and the order issuance means for issuing the order as an output;
An order issuing system characterized by comprising: The grouping means within the maximum capacity collects a plurality of orders for a batch whose target order to be summarized ends within the allowable lifetime from the start time of the last batch of a large size. Summary order issuing system according to 2. The grouping means within the maximum capacity starts the earliest when the condition setting in the setting parameter (h) further sets a condition that allows overlapping of occupation times of a plurality of tanks in the upstream process. 3. The collective order issuing system according to claim 2, wherein a plurality of orders are collected for an order from the start time of the order to the end within the allowable lifetime .