JP2007128368A - Production planning device - Google Patents

Abstract

An object of the present invention is to provide a production plan drafting apparatus that can plan a production plan that is efficient and can be carried out without difficulty.
When a material corresponding to a quantity obtained by rounding up an order quantity by the number of production lots is equal to or less than a stock quantity of the material, a material corresponding to the rounded quantity is allocated, and the order quantity is rounded by the number of production lots. When the material corresponding to the increased amount is larger than the stock amount of the material, the allocation unit 66 allocates the material corresponding to the amount calculated using the lot reduction number smaller than the production lot number, and the allocation unit allocates the material. And a planning unit 74 that prepares a production plan for a product corresponding to the material.
[Selection] Figure 3

Description

  The present invention relates to a production plan planning device, and more particularly to a production plan planning device for planning a production plan that takes into account rounding processing in units of production lots.

2. Description of the Related Art Conventionally, in order to make a production plan for a final product, there has been proposed an apparatus including means for considering a production lot unit of an intermediate product that is a part of a final product (for example, Patent Document 1). This device is a device that formulates an inventory plan for the final product, and includes means for drafting a production plan for the final product in order to keep the stock amount of the final product appropriate. In the means for preparing a production plan for the final product, this apparatus sets the quantity of intermediate products to be input according to the required amount of the final product as an integral multiple of the production lot unit of the intermediate product.
JP-A-8-241353

  However, the conventional production plan does not always allow production according to the production plan, and there is a problem that the efficiency is not fully considered in the production plan.

  First, conventional production plans do not take into account the quantity of raw materials, materials or intermediate items that can be allocated to produce the product. For this reason, there is a case where a production plan that is impossible or difficult to implement is made due to a shortage of stock of materials of the product. Such a production plan that causes a shortage of inventory of materials or the like requires labor for correcting the production plan in consideration of the shortage, or requires production close to the limit of the capacity at the production site.

  In addition, the conventional production plan uses only a production lot unit as a production unit for the production plan. Therefore, a detailed production plan cannot be made, and it is impossible to achieve both production efficiency and inventory consumption efficiency.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a production plan drafting apparatus that can plan a production plan that is efficient and can be carried out reasonably.

  In order to achieve the above object, a production plan planning apparatus according to the present invention is a production plan planning apparatus for planning a production plan according to an order, and is a material corresponding to an amount obtained by rounding up the order quantity by the number of production lots. Is less than the stock amount of the material, the material corresponding to the rounded amount is allocated, and the production lot is larger than the stock amount of the material corresponding to the amount obtained by rounding up the order quantity by the number of production lots. Provision means for allocating a material corresponding to an amount calculated using a lot reduction number smaller than the number, and planning means for planning a production plan for a product corresponding to the material allocated by the allocating means.

  The allocation means allocates the material for the allocated number from the order quantity. The “provision number” is a planned quantity of materials actually allocated among materials that can be allocated for the order. When the allocation unit determines that the material corresponding to the product quantity rounded up in the production lot unit can be allocated, the allocation unit sets the number of materials corresponding to the product quantity rounded up in the production lot unit as the allocation number. . As described above, when the number of materials corresponding to the product quantity rounded up in the production lot unit is used as the allocation number, the product is manufactured in the lot unit, so that the production efficiency is the best.

  Here, the “production lot number” is a unit quantity for producing a product, and “production lot unit” is also synonymous. “Round up” by the number of production lots means rounding up the order quantity in units of production lots. Specifically, by dividing the number of orders by units of production lots and rounding up to the first decimal place. The resulting integer is multiplied by the production lot unit.

  In addition, when it is determined that the material corresponding to the product quantity rounded up in the production lot unit cannot be allocated, the material using the lot reduction unit which is the quantity unit of the product less than the production lot unit from the material that can be allocated, etc. The number of provisions is calculated. As a result, it is possible to produce in batches to a certain extent by lot-reduction units. Therefore, a production plan that suppresses a decrease in production efficiency is created rather than producing products that can be produced from allocatable materials in units of one unit. It becomes possible. In addition, it is possible to plan a more detailed number of production than when planning production plans using only production lot units as production units, making it possible to plan production plans with excellent inventory consumption efficiency. .

  As described above, the production plan planning apparatus according to the present invention allows the production plan to be efficiently and reasonably implemented by considering the production lot unit, the quantity of materials that can be allocated, and the reduced lot unit. .

  Preferably, when the material corresponding to the amount obtained by rounding up the ordered quantity by the number of production lots is larger than the inventory quantity of the material, the allocation unit uses the lot reduction number to obtain a quantity less than the inventory quantity of the material. Calculate the maximum quantity.

  Thus, by using the lot reduction unit to allocate the inventory as much as possible, the quantity of the inventory can be reduced while maintaining the production efficiency to some extent, and the efficiency is improved.

  More preferably, when the material corresponding to the amount obtained by rounding up the order quantity by the number of production lots is greater than the stock quantity of the material, the allocation unit rounds up the order quantity by the number of production lots. The material corresponding to the amount calculated by subtracting an integer multiple of the number of lot reductions is allocated.

  More preferably, when the material corresponding to the amount obtained by rounding up the order quantity by the number of production lots is greater than the stock quantity of the material, the allocation unit rounds up the order quantity by the number of production lots. A material corresponding to the amount calculated by adding an integral multiple of the number of lot reductions to the amount obtained by subtracting the number of production lots from is allocated.

  More preferably, when the material corresponding to the amount obtained by rounding up the order quantity by the number of production lots is greater than the stock quantity of the material, the allocation unit rounds up the order quantity by the number of production lots. After adding a predetermined quantity to the quantity obtained by subtracting the number of production lots from the above, a material corresponding to the quantity calculated by adding an integral multiple of the number of lot reductions is allocated.

  With such a specific method, it is possible to allocate as much inventory as possible while using lot reduction units, and it is possible to improve the utilization efficiency of inventory while maintaining production efficiency to some extent. In addition, since a calculation method suitable for production can be adopted, it is possible to select a method with the best utilization efficiency of inventory, and the utilization efficiency of inventory can be improved.

  More preferably, the information processing apparatus further includes request acquisition means for acquiring a request date that is a date when the product is required to be completed, and the allocation means stocks the number of materials that can be allocated to the order on a date corresponding to the request date. Reserve material as a quantity.

  Considering the due date in this way makes it possible to use a precise quantity of inventory that can be allocated on the desired date. Therefore, efficient use of inventory is possible while maintaining the feasibility of production planning.

  More preferably, the allocation unit obtains the request data from the request storage unit that stores request data including a request date that is a date when the completion of the product is requested and the order quantity, and the request storage unit. A request acquisition unit, a lot unit storage unit that stores the number of production lots, a lot unit acquisition unit that acquires the production lot number from the lot unit storage unit, and a production lot acquired by the lot unit acquisition unit Temporary order quantity calculation unit that calculates the quantity of products rounded up by the number of orders received as a provisional order quantity, and a number ratio indicating the number of materials necessary for production of the product per certain quantity are stored An initial allocation number calculating unit for calculating an initial allocation number, which is the number of materials necessary for production of a product corresponding to the temporary arrangement number, from the product storage unit, the temporary arrangement number and the ratio of the number; In A comparison unit that compares the inventory amount on the date according to the request date acquired and the initial allocation number, and when the initial allocation number is less than or equal to the inventory amount, this corresponds to the rounded-up amount An allocation unit that allocates material and allocates material corresponding to an amount calculated using a lot reduction number smaller than the production lot number when the initial allocation number is greater than the inventory amount;

  Since the allocation unit has such a part, the allocation unit can calculate a material corresponding to an amount obtained by rounding up the order quantity by the number of production lots. In addition, a production plan can be made using a precise quantity of inventory that can be allocated on the desired date. Therefore, efficient use of inventory is possible while maintaining the feasibility of production planning.

  More preferably, the allocation means allocates based on the order of receipt when there is an inventory with different receipt date in the available inventory.

  More preferably, the allocation means allocates materials in order from the newly received material when there is an inventory with different warehousing dates in the available inventory.

  More preferably, the allocation means allocates materials in order from the oldest received material in the inventory when there is an inventory with different receipt date in the available inventory.

  Considering the method of inventory release in this way enables accurate management of the use of inventory.

  More preferably, the planning means calculates an arrangement number that is the number of products corresponding to the material allocated by the allocation means, and an arrangement date that is a date when a product can be produced from the material allocated by the allocation means. Develop a product production plan.

  Making a production plan that includes the number of arrangements and the date of arrangement in this way clarifies the quantity and date of products that can be arranged for the request. Therefore, it is possible to carry out production of products that can be arranged in response to requests, and to grasp the quantity of products that cannot be arranged, that is, the quantity of products that need to be dealt with separately, and make a reasonable production plan for products that cannot be arranged. It becomes possible.

  The present invention can be realized not only as a production plan planning apparatus having such characteristic means, but also as a production plan planning method having the characteristic means included in the production plan planning apparatus as steps. Or as a program that causes a computer to function as characteristic means included in the production planning apparatus. Needless to say, such a program can be distributed via a recording medium such as a CD-ROM (Compact Disc-Read Only Memory) or a communication network such as the Internet.

  According to the present invention, efficient production is possible, and a production plan that can be carried out without difficulty can be made. In addition, it is possible to create a production plan that balances production efficiency and inventory consumption efficiency.

  Embodiments of a production plan planning device according to the present invention will be described below with reference to the drawings.

  First, with reference to FIGS. 1 to 9, the configuration of a production plan planning apparatus according to the present invention will be described.

  FIG. 1 is a schematic view showing the configuration of a production management system provided with a production plan planning device 14 according to the present invention. The production management system according to the present invention makes a production plan 30 based on an order received from a customer and inventory data. The factory then performs production according to the production plan.

  The production management system according to the present embodiment includes a production plan planning device 14 according to the present invention, an input device 16 and an output device 18 connected to the production plan planning device 14, and material data having a material data storage unit 10. A terminal 11 and order terminals 24 and 26 are provided. The production planning device 14 and the material data terminal 11 are connected via an in-house LAN (Local Area Network) 12. The production planning device 14 and the order terminals 24 and 26 are connected to each other through a dedicated line, an in-house LAN 12 via the gateway 20, the Internet 22, or the like.

  The order terminals 24 and 26 are terminals for ordering products. The order terminals 24 and 26 are placed under the customer and transmit order data to the production planning device 14 according to the present invention via a dedicated line, the Internet, a LAN, or the like.

  The input device 16 is a device for inputting order data of products received from a customer by facsimile or telephone. Data input by the user to the input device 16 is received by the production planning device 14 according to the present invention. Specifically, for example, a keyboard and a mouse connected to the production planning device 14 according to the present invention.

  The output device 18 is a device that displays the data content transmitted to the production planning device 14 according to the present invention and the data content calculated based on the data content. Specifically, for example, a display, a printer, or the like.

  The material data terminal 11 is a terminal for inputting / outputting data to / from the material data storage unit 10 and managing the material data storage unit 10. The material data terminal 11 has a material data storage unit 10 directly connected to the inside or the outside thereof.

  The material data storage unit 10 is connected to the material data terminal 11 and stores material data 10a. The material data 10a is data including scheduled quantities of raw materials, materials, and intermediate products in the warehouse on a certain date.

  The production plan making device 14 makes a production plan. A production plan is made based on the order data received from the order terminals 24 and 26 or the customer input to the input / output device 16 and the material data 10 a acquired from the material data storage unit 10 via the material data terminal 11.

  In this way, by creating a production plan using an order from the customer and the material data 10a, it is possible to make a production plan in consideration of the quantity of materials that can be allocated to the order.

  FIG. 2 is a diagram showing an example of a production planning process in the production planning apparatus 14 according to the present invention. First, a provisional production plan for producing a product corresponding to the amount rounded up in units of production lots in response to an order from a customer is made. The production lot unit is a unit quantity for producing a product, which is determined from the viewpoint of management in consideration of production efficiency and inventory reduction. For example, the production lot unit is the unit quantity of a product that can be produced most efficiently when comprehensively and strategically considering the management of each company.

  Next, when materials and the like sufficient to achieve the provisional production plan can be secured, the provisional production plan is drafted as a final production plan. In addition, when it is not possible to secure materials or the like sufficient to achieve the provisional production plan, a final production plan is created by subtracting the planned number of production by the lot reduction unit. Here, whether or not materials can be secured is determined with reference to the material data 10a stored in the material data storage unit 10.

  The lot reduction unit is a unit quantity used for adjusting the production planned quantity of the product when it is impossible to make a production plan for the product corresponding to the amount rounded up in the production lot unit due to a shortage of materials. The lot reduction unit is determined by physical restrictions of production facilities, production efficiency, and the like.

  In order to explain the contents of the present invention in an easy-to-understand manner, first, explanation will be given using the specific quantities shown in FIG.

  First, the customer orders 14 capacitors 1. One capacitor 1 is assumed to be manufactured from one element body A and two lead wires. Therefore, in order to manufacture 14 capacitors 1, 14 element bodies A are required. Materials that are easily available, such as lead wires, are not considered as factors limiting production planning.

  Next, the order quantity is rounded up by the production lot unit. Here, if the production lot unit is nine, the production amount of the rounded capacitor 1 is eighteen. When a material necessary for producing 18 capacitors 1 can be secured, the production planning device 14 according to the present invention makes a production plan for arranging 18 capacitors 1. “Arrangement” means that the product is scheduled to be completed on a certain date in the production plan, the scheduled completion date of the product is referred to as “arrangement date”, and the planned completion quantity of the product is referred to as “arrangement number”. The example in this figure does not consider the due date. Therefore, the “arrangement” here is to schedule the completion of the product in the production plan.

  Subsequently, the production planning apparatus 14 according to the present invention refers to the remaining balance in order to determine whether or not the material can be secured. The “reserved balance” is the quantity of materials that can be allocated on a certain date. That is, the “reserved balance” is a quantity obtained by subtracting the quantity already scheduled to be used from the quantity of materials actually owned or scheduled to be held on a certain date. “Inventory” is also synonymous. Here, the remaining balance of the element A is 13 pieces, which is insufficient to produce 18 pieces obtained by rounding up the number of orders.

  Therefore, it is necessary to adjust the number of arrangements to meet the remaining provision. In order to adjust the number of orders, the production planning apparatus 14 according to the present invention refers to a lot reduction unit that is a unit for adjusting the number of orders. Here, the lot reduction unit is three.

  The production planning apparatus 14 according to the present invention adjusts the number of allocations by the number of materials corresponding to the lot reduction unit, thereby reducing the number of allocations to the remaining allocation. The number of provisions is the number of materials corresponding to the number of products calculated by subtracting the rounded-up arrangement number by the lot reduction unit. In the example of this figure, one material is required to produce one product. Therefore, the conversion between the number of products and the number of materials can be omitted, and the number of provisions is a quantity calculated by subtracting the rounded-up arrangement number by the lot reduction unit. In the case of the example shown in this figure, the production plan planning apparatus 14 according to the present invention subtracts three lot reduction units from 18 which is the quantity obtained by rounding up the number of orders in production lot units. The 15 reduction results are more than the 13 remaining reserves. Therefore, the production planning device 14 according to the present invention subtracts again. The 12 reduction results are less than the 13 remaining reserves. For this reason, the production plan planning device 14 according to the present invention formulates a production plan based on the fact that the number of allocations is twelve.

  Specifically, the production plan is calculation of the number of arrangements and the arrangement date. In the example of this figure, the due date is not considered, so the production plan indicates the number of orders. In the example of this figure, one capacitor 1 is produced from one element body A. Therefore, since the number of allocations is 12, a production plan with 12 arrangements is drawn up.

  Thus, an efficient production plan can be made by making arrangements using production lot units and lot reduction units. Moreover, the planning plan can be carried out without difficulty because there is no shortage of materials in the execution of the production plan.

  FIG. 3 is a block diagram showing a functional configuration of the production plan planning device 14 according to the present invention. The production plan planning apparatus 14 according to the present invention includes a material received from the material data storage unit 10 via the request data 44 created from the order data 40 received from the input terminals 24, 26 or the input device 16 and the material data terminal 11. A production plan is drawn up from the remaining allocation included in the data 10a, and the result is output to the output device 18 or the like.

  The production plan planning apparatus 14 according to the present invention includes a request storage unit 42, a request acquisition unit 46, a lot unit storage unit 48, a lot unit acquisition unit 52, a provisional order quantity calculation unit 54, and a product storage unit 56. , Initial allocation number calculation unit 60, remaining allocation acquisition unit 62, comparison unit 64, allocation unit 66, planning unit 74, plan storage unit 68, allocation remaining writing unit 76, display I / F A section 78 and a request creation section 80.

  The request creation unit 80 creates the request data 44 from the delivery lead time data 41 a stored in the delivery lead time storage unit 41 and the order data 40 from the customer, and stores the created request data 44 in the request storage unit 42. . The delivery lead time data storage unit 41 is a storage unit managed by a server or a terminal outside the production plan planning device 14 according to the present embodiment.

The request storage unit 42 stores the request data 44 created by the request creation unit 80.
The request data 44 is data indicating a final completion request at the factory, which is created based on the order data 40 from the customer. More specifically, the request data 44 is created by considering the delivery lead time included in the delivery lead time data 41 a with respect to the order data 40. “Delivery lead time” refers to the time required from delivery of a product to delivery to a customer at the factory. The request data 44 includes a product part number indicating a product type, a request number indicating a request quantity, and a request date indicating a time limit. The number of requests matches the order quantity.

  The request acquisition unit 46 acquires the request data 44. The request data acquisition unit 46 acquires the request data 44 created by the request creation unit 80 based on the order data 40 from the request storage unit 42.

  The lot unit storage unit 48 stores lot unit data 50. The lot unit data 50 includes a production lot unit and a lot reduction unit for each product.

  The lot unit acquisition unit 52 acquires the lot unit data 50 from the lot unit storage unit 48.

  The provisional arrangement number calculation unit 54 calculates the provisional arrangement number. The number of provisional orders is the quantity of products calculated by rounding up the requested number in units of production lots. That is, the calculation of the number of provisional orders is to calculate an amount obtained by rounding up the order quantity by the number of production lots.

  The product storage unit 56 stores product data 58. The product data 58 includes a product product number, a material product number indicating the type of material or the like required for the product, and a number ratio indicating the quantity of material necessary for manufacturing a unit quantity of product as a ratio.

  The initial allocation number calculation unit 60 calculates the initial allocation number. The initial number of provisions is the quantity of materials necessary for the production of a provisional number of products. That is, the calculation of the initial allocation number is to calculate the quantity of material corresponding to the quantity obtained by rounding up the order quantity by the number of production lots.

  The remaining reservation acquisition unit 62 acquires the remaining reservation, that is, the inventory amount from the material data storage unit 10 via the material data terminal 11. The material data terminal 11 is a terminal that manages the material data storage unit 10 that holds the material data 10a. The material data storage unit 10 stores material data 10a, and the material data 10a includes the quantity of materials that can be allocated on a certain date for each material product number. The remaining allocation acquisition unit 62 acquires, from the material data 10a stored in the material data storage unit 10, the quantity that can be allocated to the material necessary for manufacturing the ordered product from the request date to the due date taking into account the production lead time. To do.

  “Production lead time” is a period from receipt of materials and the like to completion of the product. The production lead time is determined by the period required to bring the material into the factory, the period from the material to the completion of the product, and the like.

  The comparison unit 64 compares the initial allocation number with the remaining allocation. The initial allocation number and the remaining allocation are compared, and the result of which is greater is delivered to the allocation unit 66.

  That is, the comparison unit 64 compares the quantity of the material corresponding to the quantity obtained by rounding up the order quantity with the number of production lots and the stock quantity of the material, and compares the quantity of the material corresponding to the quantity obtained by rounding up the order quantity with the number of production lots. One of the result that the quantity is equal to or less than the stock quantity of the material and that the quantity is larger than the stock quantity of the material is delivered to the allocation unit 66.

  The allocation unit 66 allocates materials. Based on the result of the comparison unit 64, if the remaining amount of reservation is equal to or greater than the initial number of allocations, it is determined that allocation is possible, the initial allocation number is set as the allocation number, and the material corresponding to the allocation number is allocated from the inventory. Further, when the remaining reserve is smaller than the initial allocation number, it is determined that the allocation is impossible, and the initial allocation number is adjusted by the lot reduction unit. Specifically, the lot reduction unit is converted into a material-based unit quantity, and the reduction of the unit quantity from the initially allocated number is repeated. Of the number of provisions obtained in this way, the maximum quantity that does not exceed the remaining provision is defined as the number of provisions.

  That is, when the material corresponding to the quantity obtained by rounding up the order quantity by the number of production lots is equal to or less than the stock quantity of the material, the allocating unit 66 allocates the material corresponding to the rounded up quantity and assigns the order quantity to the production lot. When the material corresponding to the amount rounded up by the number is larger than the stock amount of the material, the material corresponding to the amount calculated using the lot reduction number smaller than the production lot number is allocated.

  The plan storage unit 68 stores arrangement data 70 and error data 72. The arrangement data 70 is information relating to the products arranged by the production planning apparatus 14 according to the present invention. The error data 72 is information relating to a product that cannot be arranged by the production planning device 14 according to the present invention in response to a request for the product.

  The planning unit 74 creates the arrangement data 70 and the error data 72 and stores them in the plan storage unit 68. The number of arrangements in the arrangement data 70 is calculated from the allocation number calculated in the allocation unit 66 and the number ratio obtained from the product storage unit. Furthermore, the error data 72 is created when the number of arrangements is insufficient for the number of requests or when arrangements for requests are not made.

  The remaining allocation writing unit 76 writes the remaining allocation in which the material allocated to the material data storage unit 10 is released via the material data terminal 11. The remaining allocation written in the material data storage unit 10 is a quantity obtained by subtracting the number of allocations from the allocation remaining acquired by the remaining allocation acquisition unit 62.

  The display I / F unit 78 is an interface that receives a display request and outputs the display request to the display unit 18 such as a display connected to the server 14.

  FIG. 4 is a diagram showing the contents of the request data 44 stored in the request storage unit 42. The request data 44 is data created from the order data 40 and includes a product item number, a request date, and the number of requests.

  This figure shows an example of the request data 44 related to the capacitor, and shows an example of the request data 44 when there is one request for each of four types of products of the capacitor 1, the capacitor 2, the capacitor 3 and the capacitor 4. . The request data 44 shown in the figure indicates, for example, that the request for the capacitor 1 has a request date of August 5, 2005 and the number of requests is 9000. The same applies to the capacitor 2, the capacitor 3, and the capacitor 4.

  FIG. 5 is a diagram showing the contents of the lot unit data 50 stored in the lot unit storage unit 48. The lot unit data 50 includes a product part number, a production lot unit, and a lot reduction unit for each product.

  This figure is an example of the lot unit data 50 relating to the capacitor, and shows an example of the lot unit data 50 relating to four types of products such as the capacitor 1, the capacitor 2, the capacitor 3 and the capacitor 4. The lot unit data 50 shown in the figure indicates that, for example, the production lot unit is 5000 pieces and the lot reduction unit is 1000 pieces for the capacitor 1. The same applies to the capacitor 2, the capacitor 3, and the capacitor 4.

  FIG. 6 is a diagram showing the contents of product data 58 stored in the product storage unit 56. The product data 58 is data relating to the quantity relationship between the product and the material of the product, and includes the product item number, the material item number, and the number ratio.

  This figure is an example of the product data 58 regarding the capacitor, and shows an example of the product data 58 regarding four types of products, that is, the capacitor 1, the capacitor 2, the capacitor 3, and the capacitor 4. The product data 58 shown in this figure indicates that, for example, the capacitor 1 is manufactured from a material whose material number is the element A, and one capacitor 1 is manufactured using one element A. To express. The same applies to the capacitor 2, the capacitor 3, and the capacitor 4.

  FIG. 7 is a diagram showing the contents of the material data 10 a stored in the material data storage unit 10. The material data 10a is data relating to material loading / unloading, and includes a material product number, a loading date, the number of loadings, and a remaining provision. The remaining allocation indicates the remaining quantity of the material inventory minus the already allocated material, and indicates the maximum number of materials that can be allocated to the request.

  The data in the first row illustrated in this figure shows that 8500 pieces of materials having a material part number indicated by element A are stored on August 1, 2005, and the material part number indicated by element A. This shows that there are 8500 remaining material reserves. The data in the second and subsequent lines are the material number of the material that is received on August 1, 2005 in the second row and the material number that is indicated by element B in the third row, and the material number of the material that is received on August 2, 2005 in the third row. Shows the number of warehousing and the remaining balance for the material indicated by element B in the fourth line for the material indicated by element B on August 2, 2005.

  FIG. 8 is a diagram showing the contents of the arrangement data 70 stored in the plan storage unit 68. The arrangement data 70 is data relating to a product that can be arranged in response to a request in the production plan, and includes a product item number, an arrangement date, the number of arrangements, a material item number, and a material allocation number.

  This figure is an example of the data regarding the product arranged with respect to the request data 44 shown in FIG. Each data of this figure is demonstrated referring the request data 44 of FIG.

  First, regarding the capacitor 1, there is a demand of 9000 requests on August 5, 2005, and on the other hand, an arrangement of 8000 orders is made on August 5, 2005. Element bodies A corresponding to 8000 pieces are allocated.

  Next, regarding the capacitor 2, there is a request of 13,000 requests on August 6, 2005, and on the other hand, an arrangement of 15000 requests is made on August 6, 2005. Element B corresponding to 15000 products is allocated.

  Further, regarding the capacitor 3, there is a request number of 3,500 requests on August 8, 2005. On the other hand, there is no description of the order date, and the number of arrangements and the allocation number of the element C are zero. ing. An arrangement number of 0 means that no arrangement can be made for the request.

  Further, regarding the capacitor 4, there is a request number of 8000 requests on August 10, 2005, and on the other hand, an arrangement date of August 6, 2005 is arranged for 6500 items. Element bodies B corresponding to 6500 pieces are allocated.

  FIG. 9 is a diagram showing the contents of the error data 72 stored in the plan storage unit 68. The error data 72 is data relating to a request for which a production plan is not made, such as when there is a shortage or no arrangement for the request, and the product part number, the request date, the number of requests, and the material part number. , Including the number of provisions and arrangement errors.

This figure is an example of data relating to a product for which a production plan is not established for the request shown in FIG.
First, the error data 72 illustrated in this figure is for the capacitor 1 with a request date of August 5, 2005, a request number of 9000, a material part number of element body A, a reserve number of 8000, and an arrangement error of 1000. Including data of lack. This data shows that 1000 pieces of capacitor 1 are not available.

  Next, the error data 72 illustrated in this figure does not include error data for the capacitor 2. This is because the arrangement of the capacitor 2 is sufficient.

  Further, the error data 72 illustrated in this figure is for the capacitor 3, the request date is August 8, 2005, the request number is 8000, the material part number is C, the provision number is 0, and the arrangement error is an arrangement plan. There is data that does not stand. This data indicates that the arrangement plan for the capacitor 3 cannot be established.

  Further, regarding the capacitor 4, there is data that the request date is August 10, 2005, the request number is 8000, the material part number B is 6,500, and the allocation error is 1500 shortage. This data indicates that 1500 capacitors are insufficient.

  Such output of the error data 72 clarifies the quantity that has been arranged for the request and the quantity that cannot be arranged. For this reason, it is easy to devise appropriate measures by making a new production plan according to the material receipt schedule for items that cannot be arranged, or by applying products already arranged for other requests to the request. .

  Next, with reference to FIG. 10 to FIG. 14, the flow of processing in the production plan planning apparatus 14 according to the present invention will be described.

  FIG. 10 is a flowchart of processing executed by the production plan planning device 14. The process described below is executed on order data specified by the orderer, product part number, and delivery date.

  The request acquisition unit 46 acquires the request data 44 created and stored by the request creation unit 80 based on the received order data 40 from the request storage unit 42 (S1). The order data 40 includes a product item number, a delivery date, and a quantity.

  The product product number of the order data 40 and the product product number of the request data 44 are the same. Further, the quantity of the order data 40 and the number of requests of the request data 44 are the same.

  The request date is a date calculated by subtracting the delivery lead time from the delivery date of the order data 40. Therefore, the delivery date of the order data 40 and the request date of the request data 44 may be different.

  Next, the lot unit acquisition unit 52 acquires the product product number included in the request data 44 from the request acquisition unit 46, and acquires the production lot unit and the lot reduction unit of the product corresponding to the product product number from the lot unit storage unit 48. (S2).

  Subsequently, the provisional arrangement number calculation unit 54 acquires the number of requests from the request acquisition unit 46, and calculates the number of provisional arrangements by rounding up the number of requests by the lot production unit obtained from the lot unit acquisition unit 52 (S3). ).

  Further, the initial allocation number calculation unit 60 acquires the material product number and the number ratio corresponding to the product product number included in the request data 44 from the product storage unit 56 (S4).

  Further, the remaining allocation acquisition unit 62 acquires the remaining allocation of the material corresponding to the material product number received from the initial allocation number calculation unit 60 from the material data storage unit 10 via the material data terminal 11 (S5).

  Further, the initial allocation number calculation unit 60 acquires the provisional arrangement number obtained from the provisional arrangement number calculation unit 54, and the materials necessary for creating the provisional number of products using the previously obtained number ratio. The initial allocation number which is a number is calculated (S6).

  Subsequently, the comparison unit 64 compares the initial provision number obtained from the initial provision number calculation unit 60 with the remaining provision obtained from the remaining provision acquisition unit 62 (S7). If the initial allocation number does not exceed the remaining allocation (YES in S7), the allocation unit 66 sets the material of the initial allocation number as the allocation number to be allocated to the request, and withdraws from the allocation remaining obtained from the allocation remaining acquisition unit 62 (S11) .

  When the initial allocation number exceeds the allocation number (NO in S7), the allocation unit 66 converts the initial allocation number into a product-based quantity based on the number ratio (S8). Subsequently, the allocation unit 66 subtracts the lot reduction unit from the product-based quantity (S9). Subsequently, the allocation unit 66 determines whether or not the number of products reduced by the lot reduction unit is larger than 0 (S10).

  If the allocation unit 66 does not determine that the number of products reduced by the lot reduction unit is greater than 0 (NO in S10), the allocation unit 66 determines that the arrangement is not made, that is, the data for which the allocation number is 0 is the planning unit 74. To pass.

  When the allocation unit 66 determines that the number of products reduced by the lot reduction unit is greater than 0 (YES in S10), the allocation unit 66 indicates the number of products reduced by the lot reduction unit as a material-based quantity based on the number ratio. It is converted into the number of initial provisions (S6). Further, the allocation unit 66 compares the initial allocation number with the remaining allocation (S7). If the initial provision number does not exceed the remaining provision (YES in S7), the provisioning unit 66 sets the initial provisioning number as the number of provisions to be allocated to the request, and releases the provision number from the remaining provisions obtained from the remaining provision obtaining unit 62 ( S11).

  When the reduced provision number exceeds the remaining provision (NO in S7), the provision unit 66 converts the initial provision number into a product-based quantity (S8) and subtracts the lot reduction unit from the product-based quantity. Process (S9), a determination process (S10) for determining whether the number of products after the reduction is greater than 0, and an arrangement when the number of products after the reduction is not determined to be greater than 0 (NO in S10) The process of passing the fact that it does not stand to the planning unit 74 is executed in order, and when it is determined that the quantity after reduction is greater than 0 (YES in S10), the process of converting the number of products after reduction into the number of materials ( S6) and processing (S7) for comparing the reduced number of provisions with the remaining provisions are executed in order.

  The planning unit 74 uses the number of provisions obtained from the provision unit 66 and the ratio of the numbers obtained from the product storage unit 56 as the quantity of products that can be manufactured from the material of the number of provisions as the number of arrangements and the request date. Arrangement data 70 and error data 72 are created as the arrangement date (S12), and the process is terminated.

  In this way, the request data 44 is rounded up in lot units, and the process of reducing the number of rounded products in lot reduction units with reference to the remaining provisions is performed without reducing production efficiency and without difficulty. Enables production planning that can be done.

  With respect to such processing, the procedure for creating the data introduced in FIGS. 4 to 9 will be described with reference to FIGS.

  FIG. 11 is a diagram showing a specific processing procedure executed by the production planning device 14 according to the present invention in response to a series of order data. This is a processing procedure executed by the production planning device 14 according to the present invention when the order of the capacitor 1, the capacitor 2, the capacitor 3, and the capacitor 4 is received in order.

  This figure shows an example in which the capacitor 1 has been ordered with a delivery date of August 10, 2005 and a quantity of 9000. Next, for the capacitor 2, an example is shown in which an order with a delivery date of August 11, 2005 and a quantity of 13,000 pieces is received. Furthermore, an example is shown in which an order with a delivery date of August 13, 2005 and a quantity of 3,500 pieces is received for the capacitor 3. Further, an example is shown in which an order with a delivery date of August 15, 2005 and a quantity of 8,000 pieces is received for the capacitor 4.

  In the present embodiment, processing is performed in the order received. Therefore, first, a production plan is made for the capacitor 1 (S101), and then a production plan is made for the capacitor 2 (S102). Further, a production plan for the capacitor 3 (S103) and a production plan for the capacitor 4 (S104) are made in order.

  FIG. 12 is a diagram showing details of the processing S101 executed by the production plan planning apparatus 14 according to the present invention in response to the first order data 40. As described above, the contents of the first order are the capacitor 1 for the product, the delivery date of August 10, 2005, and the quantity of 9000 pieces. The lead time for delivery of the capacitor 1 is 5 days, and for simplicity, no holidays are considered. The request acquisition unit 46 acquires the request data 44 created from the acquired first order data 40 (S110). As shown in FIG. 4, the contents of the request data 44 are a capacitor 1 for the product, a request date of August 5, 2005, and a quantity of 9000.

  The lot unit acquisition unit 52 acquires the production lot unit and the lot reduction unit of the capacitor 1 from the lot unit storage unit 48 (S111). Specifically, the lot unit acquisition unit 52 acquires the lot unit data 50 shown in FIG. That is, the lot unit acquisition unit 52 acquires that the production lot unit of the capacitor 1 is 5000 and the lot reduction unit of the capacitor 1 is 1000.

  The provisional order number calculation unit 54 receives the production lot unit of the capacitor 1 from the lot unit acquisition unit 52. The provisional order quantity calculation unit 54 calculates the provisional order quantity as 10,000 by rounding up the desired quantity of 9000 by 5000, which is the production lot unit of the capacitor 1 (S112).

  The initial allocation number calculation unit 60 acquires the product data 58 of the capacitor 1 from the product storage unit 56 (S113). Specifically, the initial allocation number calculation unit 60 acquires the product data 58 shown in FIG. That is, the initial allocation number calculation unit 60 acquires that the material number indicating the material of the product called the capacitor 1 is the element body A, and the number ratio is 1/1.

  The remaining allocation acquisition unit 62 acquires the material data 10a through the material data terminal 11 (S114). Here, the production lead time is 4 days. Since the requested date is August 5, 2005, the material to be allocated is the material received before August 1, 2005 after subtracting the production lead time. Since the material of the capacitor 1 is the material A, the reserve remaining acquisition unit 62 specifically has 8500 remaining reserves of the material A received before August 1, 2005 as shown in FIG. To get that. However, there is no remaining provision for materials received before August 1, 2005.

  The initial allocation number calculation unit 60 calculates the initial allocation number as 10,000 since the provisional arrangement number is 10,000 and the ratio of the numbers is 1/1 (S115).

  The comparison unit 64 compares the remaining allocation of 8500 with the initial allocation of 10,000 (S116). The comparison unit 64 delivers the result of the comparison, that is, that the initial allocation number exceeds the remaining allocation to the allocation unit 66.

  The allocation unit 66 receives the result of the comparison unit 64 and reduces the initial allocation number (S117). All the reduction units in the figure show the values obtained by converting the lot reduction unit into the material-based quantity. In the processing not shown in the figure, the allocation unit 66 converts the initial allocation number into the product-based quantity by the ratio of the number, reduces the lot reduction unit from the result, and further calculates the result by the ratio of the number of the material base. It is a process to convert to. In the example of this figure, since the number ratio is 1/1, 1000 lots that are the lot reduction unit of the capacitor 1 become the same quantity, that is, 1000 pieces even when the lot reduction unit is converted into a material-based quantity. . The reduction unit in the description of this figure indicates a value obtained by converting the lot reduction unit into a material-based quantity, as described above.

  The allocation unit 66 calculates the initial allocation number to 9000 by reducing the initial allocation number from 10,000 to 10,000, and compares the remaining allocation of 8500 with the initial allocation number of 9000 ( S118).

  Since the initial allocation number exceeds the remaining allocation, the allocation unit 66 calculates a new initial allocation number by further reducing the initial allocation number (S119). The new number of initial allocations is 8000 since the initial allocation number of 9000 is reduced by 1000 as a reduction unit.

  The allocation unit 66 compares the remaining allocation of 8500 with the initial allocation number of 8000 (S120).

  Since the initial allocation number does not exceed the remaining allocation, the allocation unit 66 sets the initial allocation number of 8000 as the allocation number, and releases it from the 8500 remaining allocation. Due to the withdrawal, the remaining balance becomes 500 (S121).

  The planning unit 74 creates the arrangement data 70 and the error data 72 based on the above processing (S122), and ends the processing. As shown in FIG. 8, the arrangement data 70 includes 8000 pieces of the remaining allocation of the element A and arrangement of 8000 capacitors 1 on August 5, 2005 from the assigned material. As shown in FIG. 9, the error data 72 includes 1000 shortages for the capacitor 1 requested on August 5, 2005.

  FIG. 13 is a diagram showing details of the process S102 executed by the production plan planning apparatus 14 according to the present invention in response to the second order data 40. As described above, the contents of the second order are the capacitor 2 for the product, the delivery date of August 11, 2005, and the quantity of 13,000. The lead time for delivery of the capacitor 2 is 5 days, and for simplicity, no holidays are considered. The request acquisition unit 46 acquires the request data 44 created from the acquired second order data 40 (S130). As shown in FIG. 4, the contents of the request data 44 are a capacitor 2 for a product, a request date of August 6, 2005, and a quantity of 13,000.

  The lot unit acquisition unit 52 acquires the production lot unit and the lot reduction unit of the capacitor 2 from the lot unit storage unit 48 (S131). Specifically, the lot unit acquisition unit 52 acquires the lot unit data 50 shown in FIG. That is, the lot unit acquisition unit 52 acquires that the production lot unit of the capacitor 2 is 5000 pieces and the lot reduction unit of the capacitor 2 is 1000 pieces.

  The provisional order quantity calculation unit 54 receives the production lot unit of the capacitor 2 from the lot unit acquisition unit 52. The provisional arrangement number calculation unit 54 calculates the provisional arrangement number to 15000 by rounding up the desired number of 13000 by 5000 that is the production lot unit of the capacitor 2 (S132).

  The initial allocation number calculation unit 60 acquires the product data of the capacitor 2 from the product storage unit 56 (S133). Specifically, the initial allocation number calculation unit 60 acquires the product data 58 shown in FIG. That is, the initial allocation number calculation unit 60 acquires that the material product number indicating the material of the product called the capacitor 2 is the element body B, and the number ratio is 1/1.

  The remaining allocation acquisition unit 62 acquires the material data 10a from the material data storage unit 10 via the material data terminal 11 (S134). Here, the production lead time is 4 days. Since the requested date is August 6, 2005, the material to be allocated is the material received before August 2, 2005 after subtracting the production lead time. Since the material of the capacitor 2 is material B, as shown in FIG. 7, the reserve remaining acquisition unit 62 specifically determines that the reserve of material B received before August 2, 2005 is 2005. It is acquired that there are 12800 pieces received on August 1, and 9000 pieces received on August 2, 2005. However, there is no remaining provision for materials received before August 1, 2005.

  The initial allocation number calculation unit 60 calculates the initial allocation number as 15000 since the number of provisional arrangements is 15000 and the number ratio is 1/1 (S135).

  The comparison unit 64 compares 21800, which is the total remaining balance, with 15000, which is the initial allocation number (S136). The comparison unit 64 delivers the comparison result, that is, that the initial allocation number does not exceed the remaining allocation to the allocation unit 66.

  The allocation unit 66 receives the result of the comparison unit 64, uses the 15,000 initial allocation number as an allocation number, and withdraws it from the 21800 allocation remaining. Here, it is assumed that the withdrawal is made in order from the oldest one in the warehouse. Due to the withdrawal, the remaining provision for the goods received on August 1, 2005 becomes 0, and the remaining provision for the goods received on August 2, 2005 becomes 6800 (S137).

  The planning unit 74 creates the arrangement data 70 based on the above process (S138), and ends the process. As shown in FIG. 8, the arrangement data 70 includes the allocation of 15000 of the total remaining allocation of the element B, and the arrangement of 15000 capacitors 2 on August 6, 2005 from the allocated material. .

  FIG. 14 is a diagram showing the details of the process S103 executed by the production plan planning apparatus 14 according to the present invention in response to the third order data 40. As described above, the contents of the third order are the capacitor 3 for the product, the delivery date of August 13, 2005, and the quantity of 3500 pieces. The lead time for delivery of the capacitor 3 is 5 days, and holidays are not considered for simplicity. The request acquisition unit 46 acquires the request data 44 created from the acquired third order data 40 (S140). As shown in FIG. 4, the contents of the request data are a capacitor 3 as a product, a request date of August 8, 2005, and a quantity of 3500.

  The lot unit acquisition unit 52 acquires the production lot unit and the lot reduction unit of the capacitor 3 from the lot unit storage unit 48 (S141). Specifically, the lot unit acquisition unit 52 acquires the lot unit data 50 shown in FIG. That is, the lot unit acquisition unit 52 acquires that the production lot unit of the capacitor 3 is 4000 pieces and the lot reduction unit of the capacitor 3 is 2000 pieces.

  The provisional order number calculation unit 54 receives the production lot unit of the capacitor 1 from the lot unit acquisition unit 52. The provisional order number calculation unit 54 calculates the provisional order number to 4000 by rounding up the desired number of 3500 by 4000 which is the production lot unit of the capacitor 3 (S142).

  The initial allocation number calculation unit 60 acquires the product data of the capacitor 3 from the product storage unit 56 (S143). Specifically, the initial allocation number calculation unit 60 acquires the product data 58 shown in FIG. That is, the initial allocation number calculation unit 60 acquires that the material product number indicating the material of the product called the capacitor 3 is the element body C, and the number ratio is 1/1.

  The remaining allocation acquisition unit 62 acquires the material data 10a from the material data storage unit 10 via the material data terminal 11 (S144). Here, the production lead time is 4 days. Since the request date is August 8, 2005, the material to be allocated is the material received before August 4, 2005 after subtracting the production lead time. Since the material of the capacitor 3 is the material C, the reserve remaining acquisition unit 62 specifically, as shown in FIG. 7, has 1800 remaining reserves for the material C received before August 4, 2005. Get to be. However, there is no remaining provision for materials received before August 1, 2005.

  The initial allocation number calculation unit 60 calculates the initial allocation number as 4000 since the provisional arrangement number is 4000 and the ratio of numbers is 1/1 (S145).

  The comparison unit 64 compares the remaining 1800 reserves with the initial reserve number of 4000 (S146). The comparison unit 64 delivers the result of the comparison, that is, that the initial allocation number exceeds the remaining allocation to the allocation unit 66.

  The allocation unit 66 receives the result of the comparison unit 64 and reduces the initial allocation number (S147). All the reduction units in the figure show the values obtained by converting the lot reduction unit into the material-based quantity. In the processing not shown in the figure, the allocation unit 66 converts the initial allocation number into the product-based quantity by the ratio of the number, reduces the lot reduction unit from the result, and further calculates the result by the ratio of the number of the material base. It is a process to convert to. In the example of this figure, since the number ratio is 1/1, the lot reduction unit of the capacitor 3 is the same quantity, that is, 2000 even if the lot reduction unit is converted into the material-based quantity. . The reduction unit in the description of this figure indicates a value obtained by converting the lot reduction unit into a material-based quantity, as described above.

  The allocation unit 66 calculates the initial allocation number to 2000 by reducing the initial allocation number from 4000 to 2000, and compares the remaining allocation of 1800 with the initial allocation number of 2000 ( S148).

  Since the initial allocation number exceeds the remaining allocation, the allocation unit 66 calculates a new initial allocation number by further reducing the initial allocation number (S149). The new number of initial allocations is 0 because 2000 units as a reduction unit is reduced from the initial number of allocations of 2000 units.

  Since the initial allocation number is 0, the allocation unit 66 sets the allocation number to 0 and does not release the allocation (S150). Therefore, the remaining balance is 1800 (S151).

  The planning unit 74 creates the arrangement data 70 and the error data 72 based on the above processing (S152), and ends the processing. As shown in FIG. 8, the arrangement data 70 includes that the allocation number of the element C is 0 and the arrangement of the capacitor 3 is 0. As shown in FIG. 9, the error data 72 includes that there is no arrangement (see FIG. 9).

  FIG. 15 is a diagram showing details of the process S104 executed by the production planning device 14 according to the present invention in response to the fourth order data 40. As described above, the contents of the fourth order are the capacitor 4 for the product, the delivery date of August 15, 2005, and the quantity of 8000 pieces. The lead time for delivery of the capacitor 4 is 5 days, and holidays are not considered for simplicity. The request acquisition unit 46 acquires the request data 44 created from the acquired fourth order data 40 (S160). As shown in FIG. 4, the contents of the request data 44 are a capacitor 2 for the product, a request date of August 10, 2005, and a quantity of 8000 pieces.

  The lot unit acquisition unit 52 acquires the production lot unit and the lot reduction unit of the capacitor 2 from the lot unit storage unit 48 (S161). Specifically, the lot unit acquisition unit 52 acquires the lot unit data 50 shown in FIG. That is, the lot unit acquisition unit 52 acquires that the production lot unit of the capacitor 2 is 4000 pieces and the lot reduction unit of the capacitor 2 is 500 pieces.

  The provisional arrangement number calculation unit 54 receives the production lot unit of the capacitor 4 from the lot unit acquisition unit 52. The provisional order number calculation unit 54 calculates the provisional order number as 8000 by rounding up the desired number of 8000 by 4000, which is the production lot unit of the capacitor 4 (S162).

  The initial allocation number calculation unit 60 acquires the product data of the capacitor 2 from the product storage unit 56 (S163). Specifically, the initial allocation number calculation unit 60 acquires the product data 58 shown in FIG. That is, the initial allocation number calculation unit 60 acquires that the material number indicating the material of the product called the capacitor 4 is the element body B, and the number ratio is 1/1.

  The remaining allocation acquisition unit 62 acquires the material data 10a from the material data storage unit 10 via the material data terminal 11 (S164). Here, the production lead time is 4 days. Since the requested date is August 10, 2005, the material to be allocated is the material received before August 6, 2005 after subtracting the production lead time. Since the material of the capacitor 4 is the material B, which is the same as the material of the capacitor 2, the provision remaining acquisition unit 62 has received the goods before August 6, 2005, specifically, as shown in FIG. It is acquired that the remaining balance of the material B is 6800 pieces that were received on August 2, 2005.

  The initial allocation number calculation unit 60 calculates the initial allocation number as 8000 because the provisional arrangement number is 8000 and the ratio of numbers is 1/1 (S165).

  The comparison unit 64 compares the remaining balance of 6800 with the initial allocation of 8000 (S166). The comparison unit 64 delivers the result of the comparison, that is, that the initial allocation number exceeds the remaining allocation to the allocation unit 66.

  The allocation unit 66 receives the result of the comparison unit 64 and reduces the initial allocation number (S167). All the reduction units in the figure show the values obtained by converting the lot reduction unit into the material-based quantity. In the processing not shown in the figure, the allocation unit 66 converts the initial allocation number into the product-based quantity by the ratio of the number, reduces the lot reduction unit from the result, and further calculates the result by the ratio of the number of the material base. It is a process to convert to. In the example of this figure, since the number ratio is 1/1, 500 lot reduction units of the capacitor 4 are the same quantity, that is, 500 pieces even when the lot reduction unit is converted into a material-based quantity. . The reduction unit in the description of this figure indicates a value obtained by converting the lot reduction unit into a material-based quantity, as described above.

  The allocation unit 66 calculates the initial allocation number as 7500 by reducing the initial allocation number from 8000 to 500, and compares the remaining allocation of 6800 with the initial allocation number of 7500 ( S168).

  Since the initial allocation number exceeds the remaining allocation, the allocation unit 66 calculates a new initial allocation number by further reducing the initial allocation number (S169). The new number of initial allocations is 7000 to reduce 500 units, which is a reduction unit, from 7500 initial allocations.

  The allocation unit 66 compares the remaining allocation of 6800 with the initial allocation number of 7000 (S170).

  The allocation unit 66 calculates a new initial allocation number by further reducing the initial allocation number because the initial allocation number exceeds the remaining allocation (S171). The new number of initial allocations is 6500 to reduce the reduction unit of 500 from the initial allocation of 7000.

  The allocation unit 66 compares the remaining allocation of 6800 with the initial allocation number of 6500 (S172).

  Since the initial allocation number does not exceed the remaining allocation, the allocation unit 66 sets the 6500 initial allocation number as the allocation number, and withdraws from the 6800 remaining allocation. Due to the withdrawal, the remaining provision becomes 300 (S173).

  The planning unit 74 creates the arrangement data 70 and the error data 72 based on the above processing (S174), and ends the processing. As shown in FIG. 8, the arrangement data 70 includes allocation of 6500 remaining allocations of the base body B and arrangement of 6500 capacitors 4 on August 10, 2005 from the allocated material. The error data 72 includes the fact that 1500 shortages have occurred for the capacitor 4 requested on August 10, 2005 as shown in FIG.

  Finally, examples of screens displayed on the production planning device 14 according to the present invention will be described with reference to FIGS.

  FIG. 16 is a diagram showing an example of a screen for registering, changing or displaying the contents of the lot unit data 50. The user inputs the production lot unit and the lot reduction unit on such an input screen and sets them in advance. The user can also check and change the lot unit data 50 that has been input.

  FIG. 16 is a display example when the lot unit data 50 shown in FIG. 5 is stored in the lot unit storage unit 48. The screen example shown in FIG. 16 shows a production lot unit and a lot reduction unit of products whose product product numbers are capacitor 1, capacitor 2, capacitor 3, and capacitor 4. For the capacitor 1, the production lot unit is 5000 pieces, and the lot reduction unit is 1000 pieces. For the capacitor 2, the production lot unit is 5000 pieces, and the lot reduction unit is 1000 pieces. For the capacitor 3, the production lot unit is 4000 pieces, and the lot reduction unit is 2000 pieces. For the capacitor 4, the production lot unit is 4000 pieces, and the lot reduction unit is 500 pieces.

  When a new registration button 92 displayed at the bottom of the screen is pressed, the lot unit writing unit (not shown) displays the user input received for the new product via the input device 16 in lot units. The data is stored in the storage unit 48.

  In addition, when the change button 94 displayed at the bottom of the screen is pressed, the lot unit writing unit accepts, via the input device 16, the contents of change of the already registered production lot unit and lot reduction unit. The lot unit storage unit 48 stores the data in place of the user input.

  Further, the lot unit reading unit (not shown) reads the lot unit data 50 stored in the lot unit storage unit 48 when the search button 96 displayed at the bottom of the screen is pressed. The lot unit data 50 read by the lot unit reading unit is displayed on the screen of the display unit 18 via the display I / F 78.

  FIG. 17 is a diagram illustrating an example of a screen that displays the contents of the arrangement data 70 among the data stored in the plan storage unit 68.

  FIG. 17 is a display example when the arrangement data 70 shown in FIG. 8 is stored in the plan storage unit 68. The screen example shown in FIG. 17 shows arrangement data 70 for products whose product product numbers are capacitor 1, capacitor 2, capacitor 3, and capacitor 4.

  For capacitor 1, the date of arrangement is August 5, 2005, the number of arrangement is 8000, the material part number is element A, and the number of allocation of element A is 8000. For capacitor 2, the date of arrangement is August 6, 2005, the number of arrangements is 15000, the material part number is element B, and the number of provisions for element B is 15000. For capacitor 3, there is no order date, the number of orders is 0, the material part number is element C, and the number of provisions for element C is 0. For capacitor 4, the date of arrangement is August 10, 2005, the number of arrangements is 6500, the material part number is element B, and the number of provisions for element B is 6500.

  FIG. 18 is a diagram illustrating an example of a screen that displays the contents of the error data 72 among the data stored in the plan storage unit 68.

  FIG. 18 is a display example when the error data 72 shown in FIG. 9 is stored in the plan storage unit 68. The screen example shown in FIG. 18 shows error data 72 of products whose product product numbers are capacitor 1, capacitor 3, and capacitor 4.

  Regarding the capacitor 1, the request date is August 5, 2005, the number of requests is 9000, the material product number is the element body A, the number of allocation is 8000, and the arrangement error is 1000 short. Regarding the capacitor 3, the request date is August 8, 2005, the number of requests is 3,500, the material part number is the element body C, the number of allocation is 0, and the arrangement error is not planned. , Indicating that the arrangement plan cannot be made. Regarding the capacitor 4, the request date is August 10, 2005, the request number is 8000, the material part number is the element body B, the allocation number is 6,500, and the arrangement error is insufficient of 1500.

  As described above, the production plan designed by the production plan planning device 14 according to the present invention can be viewed by the output device 18 connected to the server.

  The production plan planning device 14 according to the embodiment of the present invention has been described above, but the present invention is not limited to this embodiment.

  For example, the request acquisition unit 46 may create the request data 42 by itself from the received order data 40.

  Further, for example, in the embodiment of the present invention, the product part number of the order data 40 and the product part number of the request data 44 are the same, but the product part numbers indicating the same product may be different from each other. For example, if the product indicated by “capacitor 1”, which is the product part number 40 of the order data, is the same as the product indicated by “CON-1”, which is the product part number of the request data 44, the correspondence between the two is stored. The production plan planning device 14 according to the present invention creates a production plan by converting the order data 40 when creating the demand data 44 by referring to the product correspondence storage unit. In this case, the product plan storage device 14 may include a product correspondence storage unit therein. The production planning device 14 may create the request data 44 with reference to an external product correspondence storage unit.

  Further, for example, in the embodiment of the present invention, when preparing a production plan for one product, only the inventory amount of one type of material is considered, but the inventory amount of two or more types of materials is considered for the production of one product. Thus, the production planning device according to the present invention can also be applied to the production planning. In this case, the production plan planning apparatus according to the present invention is configured so that each material corresponding to the amount rounded up by the number of production lots is equal to or less than the stock amount of each material. When at least one of the materials corresponding to the amount of materials allocated and the order volume rounded up by the number of production lots is larger than the stock quantity of the material, it is calculated using a lot reduction number smaller than the production lot number. Each material corresponding to the amount is allocated.

  Further, for example, the material data storage unit 10 may be provided inside the production plan planning device 14.

  Further, for example, the delivery lead time storage unit 41 may be provided inside the production plan planning device 14.

  Furthermore, for example, it is not necessary to consider lead times such as production lead time and delivery lead time. For example, a case where the time required for production is short or a case where a customer comes to pick up a product corresponds to a case where each lead time is not considered. In that case, the process executed by the production planning device 14 according to the present invention is such that the lead time is set to 0 in the above embodiment.

  Further, for example, in the process of setting the number of allocations to be less than or equal to the remaining allocation, several allocation number calculation methods can be considered.

  First, a modification of the first allocation number calculation method is as follows. When the production lot unit is an integral multiple of the reduction lot unit, the reduction lot unit is multiplied by an integer to obtain the maximum quantity that does not exceed the remaining allocation. This is a method of calculating the number of provisions. In this case, it is possible to omit the rounding process of the desired number in units of production lots.

  Next, the production lot unit may not be an integral multiple of the reduced lot unit, and will be described with reference to FIG.

  FIG. 19 is a diagram showing another example of the production planning process in the production planning apparatus 14 according to the present invention. In this figure, there are 26 orders for the capacitor 1, and the number of materials of the element A that can be allocated to this order, that is, 25 reserves of the element A, 10 production lot units, and 4 lot reduction units This is an example. As before, the number ratio of the capacitor 1 and the element body A is 1/1. That is, one capacitor 1 is manufactured by one element body A.

  According to the allocation number calculation method described in the above embodiment, the number of provisional arrangements obtained as a result of rounding up in units of production lots is thirty. By performing the subtraction by the lot reduction unit twice, the initial allocation number becomes less than the remaining allocation, and the number is 22. Therefore, the number of provisions and the number of arrangements are 22.

  In the modified example of the second allocation number calculation method, first, as much as possible is allocated from the remainder of the allocation with the number of materials corresponding to the production lot unit as a unit, and then, the lot reduction unit This is a method of stacking as many units as possible. For example, in FIG. 19, since the production lot unit is 10 and the number ratio is 1/1, the number of materials corresponding to the production lot unit is 10. If allocation is made as much as possible from the remaining 25 allocations, the allocation number is 2 units, that is, 20 units. Since the remaining balance is 25, the fraction is 5. On the other hand, the unit of the number of materials corresponding to the lot reduction unit is 4 lot reduction units and the ratio of parts is 1/1. It is a piece. The material quantity corresponding to the lot reduction unit to be stacked is 1 unit, that is, 4 pieces with respect to 5 fractions. Therefore, the total number of provisions is 24, and the number of arrangements is 24.

  In the example of FIG. 19, more materials can be allocated in the modified example than in the method described in the embodiment.

  However, if the remainder obtained by dividing the production lot unit by the lot reduction unit is accumulated first in the fraction processing of the modified example, the same result as the method of the embodiment is obtained. For example, with respect to FIG. 19, in the modification, the fraction generated by assigning a material corresponding to 2 units in the production lot unit from the remaining allocation is 5. Up to here, it is the same as the modification. Next, the remainder obtained by dividing the production lot unit by the lot reduction unit is two. These two pieces are first allocated to 5 fractions. At this point, the number of allocations is 22, and the remaining allocation is 3. It is not possible to accumulate 4 pieces, which is the number of materials corresponding to the lot reduction unit, in the remaining 3 reserves. Therefore, the number of provisions and the number of arrangements are 22. As described above, a modification example of the third allocation number calculation method is a method of calculating the allocation number by a method in which a certain quantity is first accumulated with respect to the fraction and then a material corresponding to the lot reduction unit is accumulated.

  The calculation method of these allocation numbers is determined in consideration of production facilities and management strategies. The production plan planning device 14 according to the present invention can flexibly cope with the actual situation of each user of a company or the like, and can formulate an optimal production plan for the company.

  The present invention can be applied to a production plan drafting apparatus that drafts a production plan upon receipt of an order, and is particularly applicable to a production plan drafting apparatus that drafts a production plan for order production using a production lot unit of a product.

It is a general-view figure which shows the structure of the production management system which concerns on this invention. It is a figure which shows the example of the planning process of the production plan in the production plan planning apparatus which concerns on this invention with an image. It is a block diagram which shows the functional structure in the production plan planning apparatus which concerns on this invention. It is a figure which shows the content of the request data memorize | stored in the request memory | storage part. It is a figure which shows the content of the lot unit data memorize | stored in the lot unit memory | storage part. It is a figure which shows the content of the product data memorize | stored in the product memory | storage part. It is a figure which shows the content of the material data memorize | stored in the material data storage part. It is a figure which shows the content of the arrangement data memorize | stored in the plan memory | storage part. It is a figure which shows the content of the error data memorize | stored in the plan memory | storage part. It is a flowchart of the process which the production plan planning apparatus which concerns on this invention performs. It is a figure which shows the procedure of the concrete process which the production plan planning apparatus which concerns on this invention receives a series of order data, and performs. It is a figure which shows the detail of process S101 which the 1st order data is received and the production-planning apparatus based on this invention performs. It is a figure which shows the detail of process S102 which the production plan planning apparatus which concerns on this invention receives the 2nd order data, and performs. It is a figure which shows the detail of process S103 which the production plan planning apparatus concerning this invention receives 3rd order data, and performs. It is a figure which shows the detail of process S104 which the 4th order data receives and the production-planning apparatus based on this invention performs. It is a figure which shows the example of the screen which registers, changes or displays the content of the lot unit data. It is a figure which shows the example of the screen which displays the content of arrangement data among the data memorize | stored in the plan memory | storage part. It is a figure which shows the example of the screen which displays the content of the error data among the data memorize | stored in the plan memory | storage part. It is a figure which shows in image the other example of the planning process of the production plan in the production plan planning apparatus which concerns on this invention.

Explanation of symbols

10 Material Data Storage Unit 11 Material Data Terminal 12 Internal LAN
DESCRIPTION OF SYMBOLS 14 Production planning device 16 Input device 18 Output device 20 Gateway 22 Internet 24,26 Order terminal 30 Production plan 40 Order data 41 Delivery lead time storage part 42 Request storage part 44 Request data 46 Request acquisition part 48 Lot unit storage part 50 lots Unit data 52 Lot unit acquisition unit 54 Temporary arrangement number calculation unit 56 Product storage unit 58 Product data 60 Initial allocation number calculation unit 62 Reservation remaining acquisition unit 64 Comparison unit 66 Allocation unit 68 Plan storage unit 70 Arrangement data 72 Error data 74 Planning Part 76 Reservation remaining writing part 78 Display I / F part 80 Request making part

Claims (13)

A production planning device for producing a production plan according to an order,
If the material corresponding to the quantity rounded up by the number of production lots is less than the stock quantity of the material, the material equivalent to the rounded-up quantity is allocated and the quantity ordered is rounded up by the number of production lots. A provisioning means for allocating a material corresponding to an amount calculated using a lot reduction number smaller than the number of production lots when the corresponding material is larger than an inventory amount of the material;
A production plan planning device comprising: planning means for planning a production plan for a product corresponding to the material allocated by the allocation means. When the material corresponding to the amount obtained by rounding up the ordered quantity by the number of production lots is larger than the stock quantity of the material, the allocating means uses the lot reduction number to obtain a maximum quantity equal to or less than the stock quantity of the material. The production planning apparatus according to claim 1, wherein: When the material corresponding to the amount obtained by rounding up the order quantity by the number of production lots is larger than the stock quantity of the material, the allocation unit determines the number of lot reductions from the quantity obtained by rounding up the order quantity by the number of production lots. The material corresponding to the quantity calculated by subtracting an integral multiple of is allocated. The production planning apparatus according to claim 1 or 2. When the material corresponding to the amount obtained by rounding up the order quantity by the number of production lots is larger than the stock quantity of the material, the allocation unit calculates the production lot from the quantity obtained by rounding up the order quantity by the number of production lots. The material corresponding to the quantity calculated by adding an integral multiple of the number of lot reductions to the quantity obtained by subtracting the number is allocated. The production planning apparatus according to claim 1 or 2, wherein: When the material corresponding to the amount obtained by rounding up the order quantity by the number of production lots is larger than the stock quantity of the material, the allocation unit calculates the number of production lots from the quantity obtained by rounding up the order quantity by the number of production lots. The material corresponding to the amount calculated by adding an integer multiple of the number of lot reductions is allocated after adding a predetermined fixed amount to the amount obtained by subtracting. 2. The production planning apparatus according to 2. Furthermore, it has a request acquisition means for acquiring a request date, which is the date when the product is required to be completed,
6. The production plan according to claim 1, wherein the allocating unit allocates materials by using a quantity of materials that can be allocated to the order on a date corresponding to the request date as an inventory amount. 6. Planning device. The allocation unit includes a request storage unit that stores request data including a request date that is a date when completion of a product is requested and the order quantity;
A request acquisition unit for acquiring the request data from the request storage unit;
A lot unit storage unit storing the number of production lots;
A lot unit acquisition unit for acquiring the number of production lots from the lot unit storage unit;
A provisional order quantity calculating unit that calculates the number of products obtained by rounding up the order quantity by the number of production lots acquired by the lot unit acquisition part as a provisional order quantity;
A product storage unit storing a ratio of numbers indicating the number of materials required for production of the product per certain quantity;
From the provisional order number and the ratio of the number of members, an initial provision number calculation unit that calculates an initial provision number that is the number of materials necessary for production of a product corresponding to the provisional order number;
A comparison unit that compares the stock quantity on the due date according to the request date acquired by the request acquisition unit and the initial allocation number;
When the initial allocation number is less than or equal to the inventory amount, a material corresponding to the rounded amount is allocated, and when the initial allocation number is larger than the inventory amount, a lot reduction number smaller than the production lot number is used. The production planning device according to any one of claims 1 to 5, further comprising an allocation unit that allocates a material corresponding to the amount calculated in the above. The production according to any one of claims 1 to 7, wherein the allocation means allocates the inventory based on the order of receipt when there is an inventory with different receipt dates in the available inventory. Planning device. The production planning apparatus according to claim 8, wherein the allocation unit allocates materials in order from a newly received material when there is an inventory with different receipt dates in the available inventory. The production planning apparatus according to claim 8, wherein the allocation unit allocates materials in order from the oldest stocked material when there are stocks with different receipt dates in the available stock. The planning means calculates the number of arrangements, which is the number of products corresponding to the material allocated by the allocation means, and the arrangement date, which is the date when the product can be produced from the materials allocated by the allocation means. The production planning apparatus according to any one of claims 1 to 10, wherein a production plan is created. A production planning method for creating a production plan according to an order,
When the quantity of the order quantity rounded up by the number of production lots is less than the inventory quantity, the material corresponding to the rounded quantity is allocated, and the quantity of the order quantity rounded up by the number of production lots is greater than the inventory quantity. A provisioning step of allocating material corresponding to an amount calculated using a lot reduction number smaller than the production lot number;
A production planning method comprising: a planning step of creating a plan for arranging a product from the material allocated in the allocation step. A program for creating a production plan according to an order,
When the quantity of the order quantity rounded up by the number of production lots is less than the inventory quantity, when the material corresponding to the rounded quantity is allocated and the quantity of the order quantity rounded up by the number of production lots is greater than the quantity in stock A provisioning step of allocating material corresponding to an amount calculated using a lot reduction number smaller than the production lot number;
A production planning program for causing a computer to execute a planning step for preparing a plan for arranging products from the materials allocated in the allocation step.

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