JP4318162B2 - Production schedule planning management method and production schedule planning management program - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a production schedule planning management method and a production schedule planning management program capable of taking a customer order and a prospective order, registering them in a database, and automatically answering a delivery date to a customer based on various masters.
[0002]
[Prior art]
In manufacturing sites where products are manufactured, daily activities are performed based on production schedule plans. Production schedules are information for systematically implementing production in time for scheduled delivery dates, and are created based on order information such as customer orders and prospective orders, and resource information such as processes and equipment. Is.
[0003]
[Problems to be solved by the invention]
In recent years, the production sites of products are demanded to produce a variety of products in small quantities, and the contents of the production schedule plan must be complicated as compared with the era of small products and mass production. Under such circumstances, a considerable increase in burden is required for those who are not skilled in creating production schedules. In addition, when an order is received from a customer, a delivery date reply must be sent to the customer, but a quick delivery date response is required. As for the work for answering the delivery date, the more complicated the contents of the production schedule plan, the greater the burden on the unskilled person.
[0004]
The present invention has been made in view of the above circumstances, and the problem is that even an unskilled person can create a production schedule corresponding to mass production of small varieties and promptly reply to the delivery date. A production schedule planning management method and a production schedule planning management program are provided.
[Means for Solving the Problems]
In order to solve the above problems, a production schedule planning management method according to the present invention is as follows.
Processing to receive customer order and prospective order information and store it in the order database;
Based on a reference master in which various information related to manufacturing resources are registered, the order stored in the order database is divided, and each piece of information on the divided order is stored in the order division database.
For the divided order, process development based on the basic unit master and storing in the process development database;
Based on the order information developed in the process and the production pattern stored in the production pattern database, the optimum production start date is specified, load accumulation is performed, and the result of load accumulation is stored in the production plan database;
Based on the optimum production start date, a process of creating delivery date reply information is executed by a computer.
[0005]
The operation and effect of the production schedule planning management method with this configuration is as follows. First, a customer order and a prospective order are received. A customer order is information based on an actual order received from a customer, while a prospective order is information for incorporating a production schedule into anticipation of a future order. The received order is stored in the order database.
[0006]
The standard master (master file) stores various types of information used as a basis for creating production schedules. For example, it corresponds to the required amount and time of use of manufacturing resources such as parts, processes, and equipment. Information. Based on the reference master, the order stored in the order database is divided. The divided order information is stored in the order division database. Then, a process development process is performed on the divided order based on the basic unit master. This result is stored in the process development database.
[0007]
Production patterns are stored in the production pattern database. The production pattern is a pattern setting for the order in which various products are produced. This production pattern is registered in advance in a database based on past production results and the like. Based on this production pattern and the order information that has been developed as described above, the optimum production start date is specified, and load accumulation is performed. The result of this load stacking is stored in the production plan database. The delivery date reply information can be created based on the optimum production start date.
[0008]
Each process described above can be realized by a program installed in a computer. Therefore, even an operator who is not skilled in producing a production schedule can create and manage a production schedule without requiring a large burden. In addition, it is possible to respond to the delivery date at an early stage by performing a load pile based on the optimum production start date. As a result, it is possible to provide a production schedule planning management method that enables even an unskilled person to create a production schedule corresponding to mass production of small varieties and to promptly answer a delivery date.
[0009]
As a preferred embodiment of the present invention, there is one that performs processing for changing a production schedule stored in the production plan database.
[0010]
After the delivery date response obtained as described above is sent to the customer, the customer may be asked to correct the delivery date. Therefore, by making it possible to change the production schedule that has been piled up, it is possible to easily respond to a correction request from a customer.
[0011]
As another preferred embodiment of the present invention, there is one that performs a process of displaying by a display means in a state where the production schedule plan stored in the production plan database is compared with the production results.
[0012]
By comparing and displaying the production schedule and production results, the progress of the production schedule and the degree of achievement of the delivery date can be confirmed visually and easily.
[0013]
As another preferred embodiment of the present invention, the production pattern is set so as to be a repetitive production schedule plan in a certain period and the delivery date compliance rate of the target product is maximized. can give.
[0014]
By using this production pattern, an accurate delivery date reply can be made to the customer.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of a production schedule planning management method according to the present invention will be described with reference to the drawings. FIG. 1 is a diagram showing a configuration of a production schedule planning management system for executing a production schedule planning management method.
[0016]
A large number of personal computers 1 are provided in the customer or sales department. The production schedule planning management system 2 is a computer (server), and a management program for constructing the system is installed. The personal computer 1 of the customer or sales department and the production schedule planning management system 2 are connected by a network (online order receiving system). The form of the network is not limited to a specific one, and can be constructed using a known infrastructure such as the Internet, an in-house LAN, or a telephone line. A large number of personal computers 3 are also installed in the production management department and the like, which are also connected by a network.
[0017]
Customer order information is input by the personal computer 1 provided in the customer or the sales department. The “customer order” is order information from a customer, and is information including, for example, a product (product) number, a product name, a delivery date (delivery date), a delivery quantity, a delivery address, and the like.
[0018]
Expected order information is input by the personal computer 3 provided in the production management department. The “prospect order” is arrangement information to be incorporated into a production schedule in anticipation of temporary inventory in order to level and stabilize production before receiving orders from customers. This is information that is input in anticipation of future orders taking into account past order information.
[0019]
Next, functions of the production schedule planning management system 2 (hereinafter simply referred to as “management system”) will be described. Order information input by the personal computers 1 and 3 is automatically received via the network (order receiving function). The management system 2 includes a large number of master files, a database, and a schedule plan editing tool 5. The schedule plan editing tool 5 is software for supporting production schedule planning, and know-how of a skilled person is incorporated in the system logic. In addition, a graphical screen called a Gantt chart is displayed on the computer monitor, facilitating operator input and confirmation. “Production schedule planning” refers to a schedule of production activities of products or intermediate products taking a certain period.
[0020]
Various masters (master refers to a master file; the same shall apply hereinafter) is information equivalent to a ledger, such as the required amount and time of use of manufacturing resources such as parts, processes and equipment, and corresponds to a standard master. It is. It is a file that stores information used as a reference for creating a production schedule. Also, once the master information is created, its contents do not change for a certain period of time. Of the various masters, information related to products is registered in the product pattern master. The products produced based on the production schedule are registered in the product pattern master. When a new product is developed, the product pattern master maintenance screen is opened and newly registered or corrected.
[0021]
Customer orders are sent in real time via the network. When the customer order information is received, the product pattern master is checked to check whether the product is registered. In addition, other various masters are collated to determine whether the order conditions are satisfied. In other words, it is checked whether or not the requirements for order data (product number, delivery date, delivery quantity, delivery address, etc. are provided) are satisfied. If the order conditions are satisfied, customer order information is stored in the order database 20. The prospective order is manually input by the personal computer 3 and similarly stored in the order database 20. When a customer order that does not satisfy the order conditions is received, an error message is returned to the transmission source.
[0022]
In addition, for customer orders that have been ordered, those that exceed the standard based on the product-specific standard production volume (appropriate production unit quantity) set in the various masters are automatically subjected to order division processing. The customer order that has undergone the order division and the customer order that has not undergone the order division are immediately stored in the order division database 21.
[0023]
Among the customer orders that have been split in the order splitting database 21, intermediate stock allocation is performed for the intermediate product corresponding stock item, and if it can be allocated, the response delivery date is immediately calculated based on the specified delivery date and the finish lead time. be able to. With respect to the divided orders for which the intermediate stock cannot be allocated, the process unit development and the required quantity development are performed with reference to the basic unit master, and the process developed order is stored in the process development database 22. Here, the “basic unit master” is a master that defines the physical consumption of raw materials, parts, secondary materials, man-hours, etc. used per unit of product, that is, the physical unit price per unit of product or work. Refers to a file.
[0024]
Next, the production lead time is calculated based on the order information developed in the process. Then, a production start date suitable for the delivery date requested by the customer is calculated, and the optimum production start date is specified based on the production pattern information registered in the production pattern database, and load accumulation is performed. The result of the load pile is stored in the production plan database 23. “Load pile” refers to allocating work to necessary processes to manufacture each product and intermediate product.
[0025]
For example, if the customer order is for product A and the delivery date is July 13, 2002, the order by process in the process development database 22 is registered in the production pattern database 26 at regular intervals (several minutes to 30 minutes). The most suitable date for delivery (planned date + the closest date that the finished lead time (number of days) does not exceed the delivery date (July 13, 2002)) Load pile if it enters the operation plan frame. Thereby, delivery date reply information is obtained.
[0026]
The “production pattern” will be described above. The production pattern defines which product is produced in what order among a plurality of products, and is prepared in advance based on the following four requirements. That is,
(1) It is set so that the production schedule is repeated over a certain period. Usually, it is one week, but it can be set less than one week or more than one week (for example, six months).
(2) The size of the production frame is set so that the delivery date compliance rate of the target product is maximized. Here, the delivery date compliance rate is an index representing the degree of achievement with respect to the delivery date requested by the customer, and is represented by the ratio of the quantity that can be manufactured by the delivery date specified by the customer and the total quantity that should be ordered.
[0027]
(3) The production order is set in consideration of securing productivity by reducing the number of times of setup change at the manufacturing site and time. For example, a product that uses the same main material is an integrated or continuous production frame.
(4) In addition to the above (1) to (3), based on information obtained from market, customer, company, etc. information such as demand adjustment, it is set assuming an optimal production pattern at that time. According to the method using this production pattern, the system can be efficiently maintained and operated without being affected by changes in production facilities and production conditions.
[0028]
While being conscious of the above points, emphasis is placed on operations that emphasize the experience of personnel and the latest information on the market. The demand prediction is performed based on, for example, the product shipment results for the past three years. Registration of the production pattern in the database is performed so that the person in charge satisfies the above requirements using a personal computer. It is also possible to modify / delete a production pattern once registered.
[0029]
Delivery date information is calculated based on the optimum production start date stored in the production plan database 23 described above. The created delivery date information is stored in the delivery date reply database 27. The stored delivery date reply information is checked at regular intervals, and if there is unsent information, it is extracted and transmitted. Thus, the created delivery date reply can be transmitted to the customer or the sales department by e-mail or the like.
[0030]
As described above, order confirmation processing, order split processing, process development processing, load pile processing, delivery date response processing, and delivery date response information transmission processing are automatically processed by software (production schedule planning management program). Further, the delivery date information can be calculated by specifying the optimum production start date based on the production pattern information and performing load pile. The above series of processing can be performed within one hour at the maximum. Therefore, it is possible to promptly answer the delivery date to the customer.
[0031]
FIG. 2 shows a state in which a production schedule plan loaded with a load is changed. The production schedule plan is changed by the person in charge when the customer makes a delivery date adjustment request in response to the automatic delivery date reply to the customer described above. Based on the contents stored in the production plan database 23, a work instruction database 29 for giving instructions to workers on site is created. On-site work is performed based on this. In addition, the record of the manufacturing work on site is registered in the work record database 28.
[0032]
Based on these databases, a comparison reference between the production schedule and production results can be made. This is represented by a Gantt chart screen as shown in FIG. This screen shows an operation plan (production pattern) and a production schedule in the A manufacturing line, the B manufacturing line, and the C manufacturing line. In this production pattern, the date and time of starting the manufacture of a certain product and the date and time of the scheduled end of manufacture are registered. The numerical value in the lower part of the column for production schedule is the order quantity (the total quantity of the customer order and the prospective order), and the numerical value in the upper part is the actual production quantity and the production schedule planned quantity. The quantity before accumulating results is the production planned quantity. In addition, the production pattern registration quantity is displayed in the operation plan column. The production pattern registration quantity indicates a standard quantity (calculated based on the basic unit master) that can be manufactured within that time. In this way, the production schedule plan and the actual production can be compared and displayed visually, so that the operator can immediately recognize whether or not the production schedule plan is being performed as scheduled.
[0033]
As described above, the “production pattern” is based on the production schedule plan so far, taking into account the experience of the person in charge, cans and forecasts, and sales information, and creating a production schedule plan and automating delivery date responses. be able to.
[0034]
As a known technique similar to the present invention, there is a production plan scheduling apparatus disclosed in JP-A-11-126221. In this apparatus, the concept of “production allocation pattern” is used. The production allocation pattern storage unit stores a production allocation pattern in which production orders and production time zones of all products are allocated in advance so that the switching loss and loss time of raw materials are minimized. That is, it is composed of a two-stage computer logic that automatically generates a “production allocation pattern” from the “production allocation basic information master” and automatically applies the order received and the expected order to the “production allocation pattern”.
[0035]
On the other hand, in the system according to the present invention, the “production pattern” itself is directly input using the Gantt chart screen as shown in FIG. There is a significant advantage.
[0036]
(1) Generate production patterns as computer data straight and easily without using an indirect master such as the “Production Allocation Basic Information Master” for the production schedule plan editor's experience and policy. Can do. As is known in the art, when it is composed of two stages of computer logic, it is difficult to automatically create a production schedule that satisfies the editor in terms of completeness of system logic and accuracy of input information. The degree becomes higher. Therefore, the system configuration according to the present invention can simplify the system structure and increase the efficiency of system operation.
[0037]
(2) By using the Gantt chart plan edit screen, the “production pattern” can be directly input / changed. Therefore, the operation efficiency is high.
(3) By confirming the “production pattern” on the Gantt chart plan edit screen, it is possible to grasp the image of the “production schedule plan” before the order received and the expected order actually arrive.
(4) Since it is linked to the results collection system, it is possible to constantly compare “production patterns”, “scheduled production”, “production results”, “orders received and expected orders”, and easily improve the quality of “production patterns”. It can be carried out.
[Brief description of the drawings]
FIG. 1 is a diagram showing a system configuration for executing a production schedule planning management method. FIG. 2 is a diagram showing a system configuration when changing a production schedule plan. FIG. 3 is a diagram showing a configuration example of a Gantt chart screen. [Explanation of symbols]
1,3 PC 2 Production schedule planning management system 5 Schedule planning editing tool 20 Order database 21 Order split database 22 Process development database 23 Production plan database 24 Various masters 25 Basic unit master 26 Production pattern database 27 Delivery date response database 28 Work performance database 29 Work instruction database

Claims (3)

Processing to receive customer order and prospective order information and store it in the order database;
Based on a reference master in which various information related to manufacturing resources are registered, the order stored in the order database is divided, and each piece of information on the divided order is stored in the order division database.
For the divided order, process development based on the basic unit master and storing in the process development database;
Based on the order information developed in the process and the production pattern stored in the production pattern database, the optimum production start date is specified, load accumulation is performed, and the result of load accumulation is stored in the production plan database;
Based on the optimum production start date, a process for creating delivery date reply information;
A process of displaying by a display means in a state in which the production schedule stored in the production plan database and the production results stored in the work results database are compared;
Configured to run on a computer ,
The production pattern is input using an edit screen of a screen displayed in a state where the production schedule and production results are compared, and the input production pattern is registered in the production pattern database,
The production pattern is set so that the input production pattern is a repetitive production schedule in a certain period, and the delivery date compliance rate of the target product is maximized. Scheduling management method.   The production schedule plan management method according to claim 1, wherein a process for changing a production schedule plan stored in the production plan database is performed. Production scheduling management program characterized by executing the production scheduling management method according to the computer to claim 1 or 2.

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