JPH0798741A - Integrated management method for commercial products - Google Patents

Abstract

PURPOSE:To execute the stock management in an appropriate place, and to execute the integrated management by summing up intensively logical stocks, in a coupling point in which a request leadtime and a supply leadtime are balanced at every single article. CONSTITUTION:In a distribution structure whose position extends over both sides of the upstream and the downstream around a manufacturer's head office 23, a coupling point 20, a virtual production line 28 and a virtual warehouse 29 are set. The coupling point 20 is a point where a request leadtime and a supply leadtime are balanced at every single article in many stock positions extending from a raw material position (upstream side) to a customer (downstream side). Also, this coupling point 20 becomes a reference for summing up intensively logical stocks and executing a commodity plan of every single article for executing the ordering with the production side and the distribution to the actual stock position, and the stock control is executed, based on this point 20 as a reference. At the time of this stock control, the virtual production line 28 regards virtually parts manufacturer 21, a manufacture's plant 22 and a manufacturer's head office 23 as one in order to facilitate the management of the production side.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for realizing a system for planning and managing production / sales / logistics operations.

[0002]

2. Description of the Related Art Conventionally, the planning and management of production, sales, and logistics operations have been individually planned for each operation.
No method was found to integrate sales and logistics operations for planning.

As a typical example, "the basis of production control"
There are the push-in type production method described in (Muramatsu Rintaro, Kunimoto Shobo) and the DRP method described in "Practical DRP" (Andre J. Martin, published by Nikkan Kogyo Shimbun). The indentation type production method is a method of making a plan mainly by the production side, and has an advantage that a stable production plan can be made in consideration of the supply capacity of the production side. On the other hand, there is a problem that it is difficult to reflect changes in demand trends in the production plan, and as a result, excess inventory and shortages are likely to occur.

The DRP method is a method of making a plan mainly on the demand side, and has an advantage that it is easy to reflect changes in demand trends. On the other hand, it is difficult to adjust the supply capacity on the production side, the production request suddenly occurs and the response is delayed, or an excessive load is applied.If there is a large number of production requests, determine what to start with. There is a problem that you cannot do it.

As described above, each of the conventional production methods has advantages and disadvantages, and it is difficult to optimize the whole while maintaining the consistency between the departments.

[0006] Further, as an integrated system of production, sales, and logistics operations, there is an example in which each department is connected online, data is exchanged, and each department is coordinated.
There was no idea to systematically respond to exceptional events or urgent demands, merely to share the resulting data.

[0007]

According to the conventional production management method, when a sales plan, an inventory plan, and a production plan are individually viewed,
The following problems occur, respectively. In the sales plan, it is difficult to reflect the increase and decrease in demand on the production side in order to achieve the production plan once established, or it is difficult to draw up a sales plan that sufficiently reflects the demand trend. There is a problem. The inventory plan allocates inventory on a first-come-first-served basis, so long-delivery items are linked to the inventory, and there is a large amount of safety stock in order to avoid shortages. There is a problem that it takes time.
In the production plan, there are problems that a production request suddenly occurs, and when a large number of production requests come in, it is impossible to determine what to start from.

Even if each department is simply connected online in order to solve these problems, the sales plan is on a monthly basis, the production plan is on a daily basis, or the sales plan is on a monetary basis for gross management, and the production is on a lot basis. In many cases, they do not work well because the control measures are different. Therefore, it is necessary to suddenly change the plan with daily information that jumps in from other operations, or the production speed based on lot production cannot keep up with the ever-changing demand trend. There's a problem.

[0009] Further, there are many goals among the operations such as production, distribution and sales, and the goals are often in a trade-off relationship. For example, if the sales attempt to reduce the loss of sales opportunities to improve the customer service, the inventory cost of logistics increases, and if the production lot is increased, the production efficiency increases, but the inventory cost of logistics also increases. Conventionally, there is no mechanism for evaluating which is the best in such a trade-off relationship, and priority is given to the optimization of the work of a department with strong power, and as a result, there is a problem that the overall balance is deteriorated.

The present invention has been made in view of the above problems, and realizes integrated management by systematically integrating production, sales, and logistics operations and performing inventory management at appropriate locations. is there.

Another object of the present invention is to provide a flexible inventory management method suitable for each product by changing the reference point for inventory management for each product.

[0012]

[Means for Solving the Problems] In the present invention, production, sales,
Adopt a method of systematically integrating logistics operations and adjusting the balance of each department.

The production plan, the inventory (physical distribution) plan, and the sales plan are comprehensively regarded as a "commodity flow plan", and each plan is drafted as a whole rather than independently. Therefore, if there is a change in one plan, we will establish a linkage mechanism that will be immediately reflected in the other plans. In order to realize this product sales linkage, the control scale will be unified. Since the control scale is generally used for production and distribution by individual item and by day, it is standardized by individual item and by day.

From the supply of raw materials to processing, assembly, factory warehouse,
The position where the production side and the sales side are connected in a multi-stage structure such as local warehouse, sales warehouse, and sales is set for each individual item, and this is called a coupling point. Coupling points will be located close to the customer if the product is a hot-selling product that requires immediate delivery, and close to the raw material if the product has few orders and a long delivery time. In addition, inventory management in the present invention is performed at a coupling point, and controls not only how many are currently available but also future increase / decrease schedules. The logistics side calculates the planned out-of-stock date for each product from the future inventory transition schedule and transmits it to the production side. On the production side, the delivery lead time is taken into consideration based on the planned out-of-stock date, and production is started from those with no margin. At that time, the production quota is fixed for one day, and the production is standardized every day.

Demand is always fluctuating rapidly. Even if we try to make production activities follow the fluctuations, we cannot change the production plan quickly, and there is a difference between the lots on the sales side and the lots on the production side. Therefore, the role of physical distribution is changed so that fluctuations in demand for sales are converted into a speed that production can follow, and batches are transmitted to production in batches that do not reduce production efficiency. That is, the order lot size that balances production and sales is set, lots are aggregated at the coupling point, and the above control is performed.

Further, a trade-off relationship of each work such as a decrease in sales opportunity loss and an increase in production lot to increase inventory cost is simulated, and a mechanism for evaluating the total cost is made to make a total adjustment. For example, an evaluation is made as to the balance between the cost reduction due to the reduction of the production lot and the cost increase due to the loss of the sales opportunity.

[0017]

[Function] In the inventory base of the distribution route from the production side to the dealer side, one point where the required lead time and the supply lead time are balanced for each individual item is set as the coupling point, and the coupling point is set. Since the logical inventory is aggregated and aggregated in, inventory can be easily allocated. The position of the coupling point is determined for each product, and the coupling point can be moved to the optimum stock location. An order is placed with the production side based on the inventory allocated from the aggregated value at the coupling point, and the allocated inventory quantity is distributed to the actual inventory bases.

The inventory that is scattered in the actual multi-stage / multiple bases is converted as being in one virtual stock base based on the delivery lead time and the stock amount, and based on the converted value, the coupling point Since the stock is allocated, the allocation amount of one logically virtual stock base is instructed as distribution to a plurality of actual bases.

The production capacities of a plurality of actual production bases are converted from the manufacturing lead time and the delivery lead time into one logical virtual production base, and the planned out-of-stock plan planned at the coupling point is logical. Since the production request has been ordered to one virtual production base, production is instructed to a plurality of existing production bases.

Further, the setting of the coupling point can be determined by calculating the cost minimum by simulation and determining the optimal inventory position and distribution of the inventory quantity in the multistage structure for each individual item.

[0021]

Embodiments of the present invention will be described below in detail with reference to the drawings. First, terms and variables used in this embodiment will be defined. The "single item" is the smallest classification unit of the product that can be identified by the customer. “Product type” refers to a group of single products that can be produced on the same line. The "requested lead time" is the maximum number of days a consumer can purchase the item if it is available within that number of days. In other words, it refers to the number of days that a business promotes sales to consumers with the promise of delivering each product within a certain number of days. The “delivery lead time” is the number of days from the ordering of the single item until the delivery to the designated position. The "supply lead time" is the sum of the production lead time of the single item and the delivery lead time from the factory to the warehouse serving as the inventory base.

The "coupling point" is a virtual point at which the required lead time and supply lead time are balanced for each individual product among many stock bases from the raw material base (upstream side) to the customer (downstream side). It has been set in advance. At the Coupling Point, logical inventory is aggregated, orders are placed with the production side, and allocation is made to actual inventory bases. Coupling points are moved upstream and downstream according to market trends and product characteristics. There is only one coupling point for each single item.

"Order lot size" is a unit of order quantity. Generally, it is desirable that the production side is large and the sale side is small. In the present invention, control is performed according to a certain size input by the user. "Standard inventory"
Is an ideal upper limit value of the stock quantity of each individual item in an actual warehouse. The "virtual warehouse" is an ordering unit for each individual item for logically handling an actual warehouse. In this embodiment, the order lot size is used as it is. The "production quota" is the total production amount per day for each product type.
The “out-of-stock date” is the number of days from the present time to the time immediately before the stock becomes 0 in each warehouse. It is calculated by dividing the current inventory quantity by the daily demand quantity.

<First Embodiment> First, the general concept of the present embodiment will be described. FIG. 2 is a diagram showing a distribution structure from production to distribution and sales. Generally, the distribution structure has a multi-step flow of a parts maker 21, a maker factory 22, a maker head office 23, a maker local base 24, a wholesale base 25, a retail base 26, and a customer 27. In this embodiment, the supply side of a single product in the multi-stage structure (● in FIG. 2) is called the upstream side, and the customer side is called the downstream side. In such a distribution structure,
When the flow from the downstream side is viewed, the demand requests of a large number of retail bases 26 are aggregated and are aggregated into a smaller number of wholesale bases 25 and a smaller number of maker local bases 24 and transmitted to the maker headquarters 23. At the maker head office 23, the production plan is distributed to each maker factory 22, and the necessary parts are ordered to a larger number of parts manufacturers 21 at the factory. It has a structure. In such a structure, the coupling point 20 and the virtual production line 2 are used in this embodiment.
8. Set the virtual warehouse 29. This coupling point 20 is a reference point for consolidating logical inventory, placing an order to the production side, and performing a product plan for each individual product that is distributed to existing inventory bases. Inventory control. Virtual production line 2
8 is for easy management on the production side when inventory control is performed based on the coupling point 20,
The parts maker 21, the maker factory 22, and the maker headquarters 23 are virtually regarded as one.

Next, the concept of this embodiment will be described with reference to FIG. FIG. 3 is a simplified version of the distribution structure shown in FIG. The coupling point 30 is set for each product, and the inventory is managed at this coupling point. In the example of FIG. 2, the coupling point is set at the position of the manufacturer local base 24. The virtual production line 33, which is the production side, makes a production plan for the product in response to the scheduled delivery date of the product from the coupling point 30. The virtual warehouse 32 is a warehouse having an inventory that serves as a reference for inventory management at the coupling point 30. The sales side 34, 35 is, for example, a retail base 2
6, the product sales schedule is input from the terminal device, or an inquiry is made at the time of a diving order.

At the coupling point 30, the virtual warehouse 3
The inventory of 2 is managed, and the inventory is withdrawn based on the order received from the selling side 34, 35. For example, suppose there were 250 inventories on the morning of the third day (36 in FIG. 3). If there are 500 pieces of stock on this day, 250 will be out of stock.
This will occur (37 in FIG. 3). So 3 days later 1
If 100 pieces arrive, the number will be deducted to 850 pieces and there will be no shortage (38 in FIG. 3). When this planned out-of-stock date is transmitted to the production side 33, the production side will
Make a production plan using (Material Requirement System). Specifically, the planned production completion date is grasped from the data of the planned out-of-stock date and the production lead time and the delivery lead time to the coupling point 30 are taken into consideration, and the production schedule is drafted. In addition, the planned out-of-stock date is transmitted in the form of lots already compiled, which facilitates planned production. On the other hand, from the sales side, if there is a change in delivery date or there is a jump-in order, if you inquire, the coupling point 30
It is possible to easily determine whether the product can be delivered from the inventory management table in. For changes and jump orders, the shortest delivery time can be calculated from the inventory transition schedule at the checkpoint. Figure 1
FIG. 3 is a functional block diagram showing a configuration of the present invention. Figure 1
In the figure, reference numeral 501 is an integrated management device for live products. The coupling point position indicating device 101 determines the position of the coupling point for each individual item. The priority leveling ordering apparatus 103 applies a virtual warehouse created based on ordering information obtained from the sales side to a production quota and allocates a production plan to a virtual production line. Logistics virtualization device 104
Creates a logical virtual warehouse by aggregating the information of multiple multi-stage inventory bases in reality. Production virtualization device 105
Creates a logical virtual production line by aggregating a plurality of production lines in a factory. The production physicalizing device 106
The production plan assigned to the virtual production line is expanded to the actual production line. The physical distribution physics apparatus 107 distributes the produced single item ordered from the virtual warehouse to the actual warehouse.
The simulation device 108 performs an evaluation for optimally setting parameters such as the order lot size, the standard stock amount, and the required lead time used in the present invention.

The storage device 502 is used for external data acquisition and result data reduction, and a floppy disk device, a cassette magnetic tape device, or the like is used.
It is not necessary when the integrated product management system is connected to a network such as a LAN and data is acquired and returned by file transfer. The display 503 is used for displaying various results, and is a display device or the like. Input device 504
Is a keyboard device or the like, which is used when executing instructions and inputting / changing various data. Output device 505
Is used for printing out results and the like, and is a printer device or the like.

Next, the operation of each part of FIG. 1 will be briefly described based on the PAD diagram of FIG. For details, see FIG.
Each of the following devices will be separately described with reference to PAD diagrams.

Step 401 is an initial process for using this apparatus. Input device 503 by the user
The single item master table 601 shown in FIG. 6 shows the equipment conditions such as the individual item code, the storage capacity for each warehouse, the production capacity for each production line, the required lead time for each individual item, the delivery lead time, etc. , Warehouse master table 6
02, a factory master table 603, a delivery master table 604, a warehouse-based individual product demand quantity table 605, and a factory-based product-based line-based operation schedule table 606. Each of these tables is expanded in a main memory (not shown) on the product / sales product integrated management apparatus 501 and stored in the storage device 502.

In step 402, the coupling point position indicating device 101 obtains the coupling point position for each individual product. How to determine the coupling point 30 depends on the product request achievement rate from the customer side (
It is set for each product according to the percentage of delivery that can be achieved. For example, for a product, the demand achievement rate is 50% if the delivery date is 1 day, 65% if it is 2 days, and 75 if it is 3 days.
% If there is statistical data such as 82% for 4 days, ... If the request achievement rate is set to 80%, set the point where the delivery to the retail base is 4 days as the coupling point. Good. As a result, the coupling points are set at different positions for each product as shown in FIG. 5 (a specific setting method will be described later).

In step 403, among the parameters input in step 401, the order lot size in the single item master table 601, the demand amount in the individual demand item table 605 for each warehouse, and the production in the line-by-line operation schedule table 606 for each factory The capacity, the operating rate, and the standard inventory amount in the warehouse-specific parameter table 607 are read.

In step 404, the physical distribution virtualization apparatus 10
4, the demand amount is aggregated at the coupling point for each individual item, and the table used by the priority leveling ordering apparatus 103 is updated.

In step 405, the production virtualization apparatus 10
Operation schedule table 6 for each factory and product line
The production quota for each product type is obtained from 06, and the production quota is set in the product type production capacity frame table 608.

In step 406, using the priority leveling ordering device 103, the production days used by the production physicalizing device 106 are determined by the number of spare days obtained from the physical distribution virtualizing device 104 and the production quota obtained from the production virtualizing device 105. Set the instruction data.

In step 407, the production physicalizing apparatus 10
6 is used to allocate from the production instruction data to the actual production equipment. In step 408, an instruction is given to distribute the produced products to the existing inventory bases.

FIG. 6 is a table list in the embodiment.

Next, each device will be described in more detail based on the PAD diagram. FIG. 7 is a PAD showing an embodiment of the coupling position indicating device 101. This device determines the coupling point position for each individual item.

In FIG. 7, variables are defined as follows.

L: Required lead time Li: Supply lead time (L1 is the lead time from the raw material warehouse to the customer at the most downstream side, and L2, L3, ..., Ln toward the upstream side) S: Supply Capacity Pi: Coupling inventory position (P1 is the retail base on the most downstream side, P2, P3, ..., P toward the upstream side)
n) R: Necessary amount In step 701, a loop for a single item is shown. In step 702, it is determined whether R ≦ S, and if the condition is satisfied, the process proceeds to step 703 and thereafter. Step 703
Then, the coupling point position is provisionally set to P1. When the condition of step 705 is not satisfied even once, P1 becomes the coupling point position. In step 704,
Loop i from 1 to n. In step 705, L ≧
It is determined whether or not it is Li, and if the condition is satisfied, i is incremented and the same step is executed. If the condition is not satisfied, the coupling point position is updated to Pi.

The coupling inventory position is preferably located upstream as long as the lead time required by the customer allows. Also, the shorter the required lead time, the more downstream the coupling inventory position must be. As a result, the coupling stock position is obtained on the most upstream side in the required lead time.

When Ln is shorter than L and the production capacity is sufficient to supply the required amount, the coupling inventory position is the most upstream position. This is typical build-to-order manufacturing. When L is extremely short, the coupling stock position is the most downstream.

Generally, L changes depending on the product characteristics, product life cycle, competitive relationship with other companies, demand, and competitive relationship with other companies. Therefore, by monitoring these and reflecting them in L, the coupling point can be appropriately moved to an optimum position. Each time the demand amount becomes smaller than a certain amount, L becomes longer and the coupling point moves upstream. Every time the amount exceeds a certain amount, L becomes shorter and moves to the downstream. This mechanism works similarly for the product life cycle. Here, the fixed amount refers to a lot amount or more capable of ensuring efficient production, and is represented by an order lot size.

Regarding the competitive relationship with other companies, if the competitiveness is sufficient, L can be extended even if the supply capacity is insufficient, so the coupling point moves upstream. On the other hand, when the competitiveness is insufficient, L must be shortened, so the coupling point moves downstream.

FIG. 8 is a PAD showing an embodiment of the physical distribution side virtualization apparatus 104. This device aggregates demand and inventory for each individual item. Specifically, it is to calculate the planned out-of-stock date of how many days after the out-of-stock will occur at the coupling point for each single item, and to calculate the number of spare days by subtracting the supply lead time from the planned out-of-stock date. . Step 9
In 01 and 902, the planned out-of-stock date is calculated for each individual item and each warehouse. In step 903, it is determined whether or not the corresponding warehouse is the coupling point, and in step 904, the planned out-of-stock date of the single item is obtained. The current stock quantity is 1 on the planned stockout date.
It is calculated by dividing by the daily demand. In step 905, the supply lead time is subtracted from the planned out-of-stock date calculated in step 904 to calculate the number of days left for each individual product. In the present invention, as described in the above example, the basic idea is to collect all the inventory at the coupling point for each single item. However, depending on the characteristics of the product, it may be better to have a backup inventory at the rear location without concentrating the inventory at the coupling point. For example,
The coupling point is the child warehouse, but the order lot size is larger than the allowable space of the child warehouse, or the order lead time becomes too long. In such a case, the standard inventory amount of the child warehouse is set small, and the rest is held in the mother warehouse as backup inventory. The following describes an example where the coupling point is a child warehouse, but the mother warehouse has a backup inventory.

FIG. 9 is a diagram showing an example thereof. The planned out-of-stock date is calculated for each child warehouse, and orders from the child warehouse are made to the mother warehouse. In the mother warehouse, the inventory is subtracted from the order from the child warehouse, and the virtual warehouse is created by setting the number of days until just before the stock runs out as the planned stockout date. In this example, the coupling point is the child warehouse, but it is assumed that the child warehouse has a backup because the capacity of the child warehouse is small.

The order lot size is 50, the standard inventory amount is 20 for the child warehouse 1, 30 for the child warehouse 2, 30 for the child warehouse 3, and the daily demand for the child warehouse is 10 for each warehouse. The current stock volume is the same as the standard stock volume. First, for each child warehouse, the daily demand forecast is subtracted from the current inventory amount, and the expected number of days until out of stock is generated. The child warehouse 1 has a planned out of stock days of 2, the child warehouse 2 has a planned out of stock days of 3, and the child warehouse 3 has a planned out of stock days of 3 days. The stock in the mother warehouse becomes 0 on the 3rd and 4th days, so the planned stockout date of the mother warehouse becomes the day before 0, that is, the 2nd and 3rd days.

FIG. 10 is a PAD showing an embodiment of the production virtualization apparatus 105. In step 1101, the production capacities of actual production lines are collected for each product type. Step 11
In 02, the production capacity obtained in step 1101 is multiplied by the operating rate to obtain the production quota for each product type. In step 1103, the production quota is adjusted by comparing with the demand amount in the scheduled period.

FIG. 11 is a PAD showing an embodiment of the priority leveling ordering apparatus 103. The physical distribution virtualization apparatus 104 calculates the expected number of days until the product runs out and the number of days remaining from the supply lead time for each individual product to the start of production. In step 1201, the number of surplus days obtained for each virtual warehouse for each individual product is accumulated for each product type. Step 1
In 202, the surplus days for each product type are rearranged in ascending order to create an order priority vector. By the production virtualization apparatus, there are as many virtual lines that perform production corresponding to the types as the number of types, and the daily production amount (production quota) is set for each. In step 1203, according to the ordering priority order obtained in step 1202, a single item order up to the quantity corresponding to the production quota is accepted. This is the allocation to the virtual production line. In step 1204, the production ordered items are added to the actual inventory amount as the order backlog. In addition, each individual item order follows the entered order lot size.

The order lot size from the virtual warehouse is mainly determined by the facility requirements on the factory side. In other words, the size is not so large that the production efficiency is remarkably reduced due to frequent changeovers. In addition, one lot is made even if it is expected that a small amount of stock will be less than the lot size. The rest will be in stock, but since the order will be in accordance with actual sales trends, it will be possible to significantly reduce the inventory as a whole. As described above, the production side can plan and manage the process plan with a margin. In addition, the daily production will be stable and production will be leveled. The logistics side will receive inventory replenishment by the expected out-of-stock date, and each single item will show a turn corresponding to the demand.

FIG. 12 is a PAD diagram showing an embodiment of the production physicalizing apparatus 106. In step 1301, order lots are collected for each product type. In step 1302, the margin of daily production quota is calculated. This represents how much the preset production quota is allowed to exceed in a day. Steps 1303 and thereafter are an example of a procedure for obtaining a fixed amount per day. If the quantity obtained by sequentially adding lots having the next rank to the order obtained by the priority leveling ordering device falls within the upper limit obtained in step 1302, it is set as the fixed quantity, and if not, the initial lot is set. Let For setting the daily frame, an existing production management system may be used, and various other methods are possible.

FIG. 13 is a PAD diagram showing an embodiment of the physical distribution physicalizing apparatus 107. At step 1401, first, the standard inventory quantity is sorted into the warehouse where the order is generated. In step 1402, the remaining amount in step 1401 is sorted out. The method is to sort the child warehouses with the following priority in order within the range that does not exceed the standard inventory amount, and to sort all to the mother warehouse and then to dispose of them according to the planned stockout date of each child warehouse. is there.

The method of planning and managing the production / sales / distribution work described above is effective even when applied to the limited range of the multi-stage structure in FIG. For example, even if one stage of a maker factory is taken, it consists of many manufacturing processes and has a multi-stage structure. Find the coupling point where the demand lead time (delivery date) on the demand side and the production lead time on the supply side (process time for producing products from parts) are balanced, and use this point as a logical inventory point to characterize the manufacturing process (lot It is possible to perform production management by using the priority leveling ordering device of the device 103 according to size and process time).

<Embodiment 2> In the above-described embodiment, an example has been described in which the user sets the standard inventory amount and the order lot size. However, in order to operate the present invention effectively, it is necessary to set these values appropriately,
It is very difficult to determine whether it is the optimum value.
Therefore, a method of obtaining the optimum value using the simulation device 108 will be described below. In the following, details of one embodiment relating to the simulation apparatus 108 of the present invention will be described.

FIG. 14 is a block diagram showing the internal structure of the simulation apparatus 108 according to this embodiment. 14
Supplementary explanation will be given for each block in.

The execution control function of 1621 takes charge of operation control / control of the entire simulation apparatus. A data management function 1622 manages basic data necessary for the operation of the simulation apparatus main body, execution results, and the like. 16
The data acquisition function 23 is a part that performs external data acquisition / initial processing for initial simulation or updating of basic data and the like due to changes over time (months). 16
The order simulation function 24 is a central part of the present apparatus, and performs simulation based on basic data to obtain inventory transition, order occurrence status, and the like.

In the present embodiment, the processing is performed for each day, but it may be performed in units of time or longer. It depends on whether the calculation precision is emphasized or the load on the simulation device is reduced and the processing time is shortened. Here, the virtualization calculation function of 1641 aggregates demand and inventory based on the above-mentioned virtualization method. The specific processing contents include clarification of the replenishment request by grasping the whole inventory status including the order backlog and grasping the out-of-stock prospect. Then 16
The order calculation function 42 determines the order contents based on the above-mentioned ordering method. Further, the physical calculation function of 1643 redistributes the order result into demand and inventory based on the above-mentioned physical method. Specific processing contents include clearing of the order backlog, inventory allocation, and individual inventory withdrawal to demand. The evaluation calculation function of 1625 is based on the stock transition, the occurrence status of orders, etc. obtained by the order simulation.
This is a part that generates quantitative evaluation results such as delivery costs, inventory costs, opportunity loss costs, etc., and outputs them to a display or printer. The data adjustment function 1626 is a part that adjusts data (accepts changes) in order to obtain the minimum total cost or an acceptable level balance evaluation result. Finally, the data reduction function of 1627 is a part of returning the improvement data optimized by the simulation to the acquisition source.

For simplification, the model of the embodiment of the simulation apparatus 108 is assumed to have a two-stage inventory structure including one mother warehouse and a plurality of child warehouses. It is considered that the demand from sales (sales offices, etc.) is met by the forward inventory of each child warehouse and the backward inventory of the mother warehouse. Each child warehouse places a replenishment order with respect to the mother warehouse, and after a predetermined number of days (delivery lead time from the mother warehouse to each child warehouse), receives a replenishment of a predetermined amount (standard inventory quantity for each individual child warehouse). In addition, the mother warehouse makes a replenishment order to the factory, and after a predetermined number of days (production lead time for each individual product + delivery lead time from the factory to the mother warehouse), receives the ordering lot size for each individual product × N. The handling data is the same as the table in FIG. Each data is assumed to be a key sequence file. The highlighted portion in the figure indicates each key.
Some data, such as the simulation period, contains only one data without a key. In particular, the replenishment request as an interim result indicates the result of the aggregation of demand and inventory, and the number of spare days in anticipation of supply days for each individual item by warehouse (replenishment request if replenishment is not received within this number of days) and replenishment request Think of it as a list of quantities. In addition, it is possible to give a daily variable demand instead of a uniform demand as the demand amount for each individual item for each warehouse.

FIG. 15 is a PAD showing the whole processing procedure of the simulation apparatus 108 in the embodiment. A supplementary explanation of FIG. 15 (entire PAD) will be given below. The entire processing procedure from the start to the end of the simulation will be described.

First, in step 1710, a judgment as to whether it is necessary to perform data acquisition for the first time or for changes over time (month) is accepted, and if data acquisition is instructed, basic data acquisition / initial processing in step 1800 is performed. Here, a supplementary explanation will be given using FIG. 16 (data acquisition PAD). Step 1810 is a part for external data acquisition and initial processing for the initial simulation or basic data update due to secular / monthly changes. In this embodiment, it is assumed that an auxiliary storage medium such as a floppy disk or a cassette magnetic tape is used as the acquisition method, and the data has been converted into a predetermined data format by the acquisition source. Next step 1
At 810, basic data (primary data) is acquired and updated. The target data is a single item master, a warehouse master, a factory master, a delivery master, a demand amount for each individual item for each warehouse, an operation schedule for each product type for each factory, a simulation period, and the like. Next, in step 1820, basic data (secondary data) is acquired and initial processing is performed. The following calculation formula is applied to the coupling point parameters for each warehouse in the target data. Mother warehouse ・ Supply lead time for each individual product = Production lead time for the corresponding single product + Delivery lead time from the factory to the mother warehouse. And supply lead time for each child warehouse and each individual product =
Delivery lead time from the mother warehouse to the child warehouse. In addition, the following formula is applied to the production capacity limit for each type of target data.

Production capacity frame of each product type = Σ (production capacity of each factory, product type, and line × operation rate of the line).

Further, in step 1830, evaluation calculation data is acquired. The target data are: setup change cost per lot by product type, out-of-stock loss cost per out-of-stock item per single item, delivery cost per individual item per warehouse, storage cost per individual item per warehouse, The ordering fee per ordering, the weighting coefficient of each cost, and the like.

Next, in step 1722 of FIG. 15, after the execution results such as inventory transition, order status, each cost, etc. and the evaluation result are cleared, the set simulation period (30,
The order simulation of step 1900 is repeated for 60 days or the like. Here, a supplementary explanation of FIG. 17 (order simulation PAD) will be given.

The ordering simulation is a central part for performing a simulation based on basic data to obtain inventory transition, ordering occurrence status, and the like. In step 1910, the order simulation for the nth day and the first day is a sequential process for each product group, and the following process is repeated for each product group for all product groups. First, after the replenishment request is cleared in step 1911, step 20 is performed for each individual product belonging to the product type group.
The virtualization calculation of 00 (aggregation of demand and inventory regarding the single item) is repeated. Next, after the order calculation in step 2100 of FIG. 19 (decision of order contents regarding the product type group) is performed, for all single products belonging to the product type group,
The physical calculation in step 2200 of FIG. 20 (re-deployment of the ordering result regarding the single item into inventory and demand) is repeated for each individual item.

A supplementary explanation of FIG. 18 (virtualization calculation PAD) will be given below. The virtualization calculation is a part that aggregates the demand and the inventory for each single item under normal processing on the nth day. Specifically, we clarify the replenishment request for the child warehouse, which is required from the comparison between the stock and demand of the child warehouse, and the replenishment request on the mother warehouse side to supplement this with the replenishment from the mother warehouse.

The following steps 2011 to 2017 are repeated for each of the child warehouses.

In step 2011, the planned inventory is initialized. However, from the inventory transition, the initial planned inventory value is the inventory of the child warehouse, the single item, and the inventory amount on the nth day. From the n-th day onward until the designated last day of simulation or until a predetermined number of replenishment requests are obtained, step 2013-
Repeat 2017 every day. In step 2013, the transition of the planned inventory is provisionally tracked. However, the calculation formula is (i +
1) Planned inventory after n days = Planned inventory after i days + No. (n + i)
Scheduled delivery on the first day (provisional addition of order backlog) -Demand volume for the warehouse and the single item (provisional payment to demand). Step 20
At 14, the possibility of out-of-stock occurrence is determined, and if the out-of-stock is out (planned stock <0), steps 2015 to 2017 are executed. In step 815, the number of spare days (absolute replenishment date) is calculated. However, surplus days = estimated number of days until out-of-stock occurrence i-supply slave time of the child warehouse and the individual product.
In step 2016, the supplement request for the child warehouse is additionally registered. However, the child warehouse, the single item, and
It is assumed that the unit replenishment amount of the surplus days i = the standard stock amount of the warehouse and the single item, and the required number of units = 1. In step 2017, as a provisional replenishment measure, the replenishment request amount is provisionally added to the planned inventory. Steps 2020 to 2036 are processes for the mother warehouse. In step 2020, the planned inventory is initialized. However, from the inventory change, the planned inventory initial value = mother warehouse / single item / inventory quantity on the nth day. From the n-th day onward until the designated last day of simulation or until a predetermined number of replenishment requests are obtained, steps 2031 to 2031
Repeat 2035 every day. In step 2031, the transition of the planned inventory is provisionally tracked. However, the calculation formula is (i +
1) Planned inventory after n days = Planned inventory after i days + No. (n + i)
It is scheduled to be delivered on the day (temporary addition of the order backlog) -to be delivered on the (n + i) th day (temporary delivery to the child warehouse).

Here, the payout schedule on the (n + i) th day = Σ
Each child warehouse, the single item, and the number of spare days are the unit replenishment amount for i days. Further, all requests with spare days ≦ 0 are processed as the same as spare days = 0.

In step 2032, it is determined whether or not the product is out of stock, and if the product is out of stock (planned stock <0), step 2
033 to 2035 are executed. In Step 2033,
Calculate the number of spare days (absolute refill date). However, surplus days = expected number of days until occurrence of out-of-stock i-mother warehouse-supply lead time for the single item. Steps 2035 and 2036 are repeated until the shortage is avoided (planned stock ≧ 0). still,
This is compatible with multiple orders when the order lot size is small.

In step 2035, the mother warehouse replenishment request is additionally registered. However, in the replenishment request, the unit replenishment amount of the mother warehouse, the single item, and the number of spare days i = the order lot size of the single item. In addition, one unit is added to the requested number. In step 2036, the unit replenishment amount is provisionally added to the planned inventory as a provisional replenishment measure.

A supplementary explanation of FIG. 19 (order calculation PAD) will be given below. The order calculation is a part for determining the order contents regarding the product group being processed in order on the nth day. Specifically, the request for replenishment of the mother warehouse is assigned to the production capacity frame in the order of the number of surplus days. At step 2110, the order acceptable amount is initialized. However, from the production capacity frame for each product type, the order acceptable amount = the production capacity frame for the product type. Step 2120
Sort the replenishment requests from the mother warehouse in ascending order of the number of spare days. In step 2130, according to the number of spare days,
Repeat requests for each mother warehouse replenishment request. The following steps 2132 to 213 are performed by the number of replenishment requests.
Repeat 5. It should be noted that this is compatible with a multiple-unit order when the order lot size is small. In step 2132, it is determined whether or not the order is accepted. However, the judgment formula follows.

Order Acceptable Amount> Unit Replenishment Request Replenishing Amount In step 2134, the order acceptable amount is subtracted from the order acceptable amount.

In step 2135, the new order backlog is additionally registered. However, the replenishment request amount is added as a new order backlog to the delivery amount on the mother warehouse, the single item, and the (n + mother warehouse, supply lead time of the single item) day in the inventory transition.

A supplementary explanation of FIG. 20 (physical calculation PAD) will be given below. The physical calculation is a part of re-developing the ordering result for each single item under normal processing on the nth day into inventory and demand. Specifically, in consideration of the replenishment request by comparing the inventory of each warehouse with the demand, the allocatable inventory including the order backlog is distributed. At step 2210, the order backlog in the mother warehouse is erased. However, in the inventory transition, the mother warehouse, the single item, and the nth item
Add the delivered amount to the inventory amount on the day. In step 2220, the replenishment requests from the child warehouses for the single item are sorted in ascending order of the number of spare days. Steps 2231 to 223
In 4, the replenishment request for the child warehouse is repeatedly processed for each one in the order of the number of surplus days. In step 2231, it is determined whether or not replenishment is necessary. When it is necessary to replenish the child warehouse (margin days ≤ 0), the following steps 2232 to 2234 are performed.
To execute. By setting the number of spare days ≦ N here, it is possible to have a safety stock equivalent to the number of days (for N days). In step 2232, it is determined whether or not the replenishment request can be accepted. However, the judgment formula is mother warehouse / single item / stock amount on the nth day ≧ unit replenishment amount of the request. Steps 2233 and 22 when stock can be delivered from the mother warehouse to the child warehouse
34 is executed. In step 2233, the order status is additionally registered. However, the replenishment request amount is added to the order amount of the child warehouse, the single item, and the nth day in the order status. In step 2234, the inventory transition is updated. However, in the inventory change, the replenishment request amount is reduced from the stock amount on the mother warehouse, the single item, and the nth day, and the replenishment request amount is added to the delivery amount on the mother warehouse, the single item, and the nth day. The replenishment request amount is added as a new order backlog to the delivery amount on the day of the warehouse, the relevant single item, the (n + the relevant subsidiary warehouse, the supply lead time of the relevant individual item). Steps 2241 to 2244 are repeated for each child warehouse for each warehouse. Step two
At 241, the order backlog of the child warehouse is erased. However, the delivery amount is added to the inventory amount of the child warehouse, the single item, and the nth day in the inventory transition. In step 2242, it is determined whether or not the stock can be delivered to the demand. However, the judgment formula is that the child warehouse, the single item, the inventory amount on the nth day ≧ the demand amount of the child warehouse, the single item.

The virtualization / physicalization method described before the embodiment,
And a series of order simulations based on the ordering method. Then, in step 2300 of FIG. 15, various cost calculations are performed based on the result of the ordering simulation, and the result is output as an evaluation result.

A supplementary explanation of FIG. 21 (evaluation calculation PAD) will be given below. The evaluation calculation is a part for calculating and outputting various costs based on the inventory transition obtained by the order simulation, the occurrence status of orders, and the like. Step 2310
Then, the basic numerical value is acquired prior to cost calculation. However, from the ordering status, the total number of ordered lots by product type, the total number of ordered items by warehouse, individual items, the total number of orders, and the average ordering interval by individual item by warehouse are calculated. The average ordering interval for each individual warehouse =
Simulation period ÷ total number of orders for individual items by warehouse. Also, from inventory changes, the total number of out-of-stock items by individual item, the average inventory amount by individual item by warehouse, etc. are obtained. In step 2320, each cost is calculated. However, here, for the sake of simplification of the embodiment, only a simple example in which it is possible to use a basic unit such as one piece of missing product or one piece of individual product is shown, and its calculation formula is illustrated below.

Production cost = setup change cost per lot by product type × total order lot number by product type Opportunity loss cost = out-of-stock loss cost per single stock item ×
Total number of out-of-stock items by item Delivery cost = Delivery cost per item for each item by warehouse × Unit order quantity by item by warehouse ÷ Average ordering interval by item by warehouse Inventory cost = Storage cost per item by item by warehouse × Warehouse Average stock amount by individual item Office work cost = ordering work cost per ordering x total number of orders Next, in step 2330, the total cost is calculated. However, total cost = Σ (each cost × weighting coefficient for each cost). In step 2340, each cost and total cost as a calculation result are output to a display device or a printer. Note that each cost has already been cleared in step 1722 each time.

Here, until a satisfactory evaluation result is obtained,
Or until the forced termination instruction is accepted, step 24
After the data adjustment (change acceptance) of 00 is executed, the simulation is repeated.

A supplementary explanation of FIG. 22 (data adjustment PAD) will be given below. The data adjustment is a part for adjusting the data (accepting changes) in order to obtain the evaluation result of the minimum total cost or the acceptable level balance. In step 2411, selection of adjustment data is accepted until there is an end instruction (forced termination), and each adjustment (change acceptance) in steps 2412 to 2418 is repeated according to the selection result. In step 2412, when the warehouse-by-individual coupling point parameter is selected, a change in the standard inventory amount is accepted. In step 2413, when the single item master is selected, the production lead time and the order lot size are changed. In step 2414, when the delivery master is selected, the delivery lead time change is accepted. In step 2415, if the demand quantity for each individual warehouse is selected, the demand quantity change is accepted. Step 24
In 16, when the operation schedule for each product type for each factory is selected, a change in the operation rate is accepted. In step 2417, when the simulation period is selected, the change of the period is accepted. In step 2418, when the evaluation calculation data is selected, the change of the evaluation calculation data or the weighting coefficient is accepted. Then step 2420
Then, the basic data (secondary data) is updated. However,
It refers to recalculation of supply lead time when there is a change in lead time, or recalculation of production capacity by product type when there is a change in line operation schedule.

Finally, in step 1730 of FIG. 15, a judgment as to whether data reduction is necessary is accepted, and if data reduction is instructed, simulation result reduction in step 2500 is performed.

A supplementary explanation of FIG. 23 (data reduction PAD) will be given below.

The data reduction is the result of simulation.
This is a part for returning the optimized improvement data to the acquisition source.
In the present embodiment, an auxiliary storage medium such as a floppy disk or a cassette magnetic tape is used as the return method, and the data is reconverted into a required data format at the return destination. In step 2510, basic data is output. However, the target data and its important items are the reference inventory amount of the coupling point parameter for each warehouse, individual item, the production lead time and order lot size of the individual item master, the delivery lead time of the delivery master, the demand amount for each individual item for each warehouse, and each factory. It is the operation rate, etc., which is scheduled to be operated by product line and line.

According to this embodiment, based on the above-mentioned virtualization / physicalization method and ordering method, the ordering and the transition of the stock in the multi-stage stock are simulated, and the occurrence status of out-of-stock items, delivery cost, etc. Since it is quantified as a cost, it is possible to optimize the way of holding inventory in multi-level inventory from the viewpoint of total cost minimum or strategic cost balance.

In the present embodiment, the process of re-simulation is executed after the data adjustment 1626 accepts changes of various basic data and the like, but the number of data to be adjusted is large and each data is completely Not irrelevant. Therefore, an example in which the efficiency and labor saving of the optimum solution search are achieved by the binary adjustment type automatic adjustment processing will be described below.

FIG. 24 is a conceptual diagram showing a binary search type adjustment procedure.

In the figure, the purpose is to obtain data (approximate value) that minimizes the total cost.

The adjustment range is within twice the initial value of the data.
The curve is an example of a graph showing the relationship between the data and the total cost while fixing other data. By using the initial value of the data as the first dividing point, comparing the total costs for the middle points of the left and right two areas, and narrowing the search range by setting the middle point on the side that can reduce the total cost as the next dividing point, It is intended to surely improve the data accuracy.
, '~ Indicate the search points.

FIG. 25 is an example of a PAD showing the data adjustment procedure when the binary search type automatic adjustment is performed. fundamentally,
By repeating the simulation and comparing the results twice for each piece of data to be adjusted, the accuracy of the data is improved and the convergence to the optimum solution is achieved step by step. The division level of step 1532 starts from the initial division level 1 and is 1 / (2 N
The search range will be narrowed to the power of 2 times.

The effect of this modification is to make the search for an optimal solution efficient.
It is possible to save labor. Further, it is possible to obtain a data group for realizing a desired cost value by making the neural network learn the relationship between each data and the total cost in the modified example.

In the present embodiment, the delivery route is fixed for simplification, but the delivery route can be set / changed for each individual item and reflected in the order simulation.
It is possible to optimize the inventory position and inventory volume of multi-stage inventory, including delivery routes.

In the concrete processing, according to the set delivery route, the replenishment requests are sequentially collected from the demand delivery source to the upstream delivery source, and at the same time, the most upstream delivery source is sequentially stocked. Allotment shall be made.

[0091]

As described above, according to the present invention, it is possible to realize integrated management by systematically integrating production, sales, and logistics operations and performing inventory management at an appropriate place. is there.

[Brief description of drawings]

FIG. 1 is a functional block diagram showing the configuration of a product / sales integrated management system according to a first embodiment.

FIG. 2 is a diagram showing a distribution structure according to the first embodiment.

FIG. 3 is a conceptual model diagram in the first embodiment.

FIG. 4 is a PAD diagram showing the basic flow of the first embodiment.

FIG. 5 is an example of setting a coupling point according to the first embodiment.

FIG. 6 is a table list according to the first embodiment.

7 is a coupling point position pointing device 10 of FIG.
PAD diagram showing operation 1

8 is a PA showing the operation of the physical distribution virtualization apparatus 107 of FIG.
Figure D

9 is a diagram showing an example of the physical distribution virtualization apparatus 104 of FIG.

10 is a diagram showing the operation of the production virtualization apparatus 105 of FIG.

11 is a diagram showing the operation of the priority leveling ordering device 103 of FIG.

FIG. 12 is a diagram showing an embodiment of the production physicalizing apparatus 106 of FIG.

FIG. 13 is a diagram showing an embodiment of the physical distribution physicalizing apparatus 107 of FIG.

FIG. 14 is a block diagram showing the internal configuration of the simulation apparatus according to the second embodiment.

FIG. 15 is a PAD diagram showing the overall processing procedure of the simulation apparatus in the second embodiment.

FIG. 16 is a PAD diagram showing a data acquisition processing procedure according to the second embodiment.

FIG. 17 is a PAD diagram showing a processing procedure of order simulation in the second embodiment.

FIG. 18 is a PAD diagram showing a processing procedure of virtualization calculation according to the second embodiment.

FIG. 19 is a PAD diagram showing the order calculation processing procedure in the second embodiment.

FIG. 20 is a PAD diagram showing the procedure of the physicalization calculation in the second embodiment.

FIG. 21 is a PAD diagram showing a processing procedure of evaluation calculation in the second embodiment.

FIG. 22 is a PAD diagram showing a processing procedure of data adjustment in the second embodiment.

FIG. 23 is a PAD diagram showing a data reduction processing procedure according to the second embodiment.

FIG. 24 is a conceptual diagram showing a binary search type adjustment procedure in a modification of the second embodiment.

FIG. 25 is a PAD diagram showing a processing procedure of data adjustment in the modification of the second embodiment.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Takayuki Matsune 12 890 Kashimada, Saiwai-ku, Kawasaki-shi, Kanagawa 12 Information Systems Division, Hitachi, Ltd. (72) Keiji Tadokoro 890 Kashimada, Saiwai-ku, Kawasaki, Kanagawa 12 Information Systems Division, Hitachi, Ltd.

Claims (7)

[Claims] 1. A point (hereinafter referred to as a coupling point) in which a required lead time and a supply lead time are balanced for each individual product in an inventory base in a distribution route from a production side to a sales side. The logical inventory is obtained and aggregated at the coupling points, the inventory is allocated from the aggregated value, the production side is ordered, and the allocated inventory quantity is distributed to the actual inventory bases. An integrated management method for commercial products, which is characterized by the following. 2. The method according to claim 1, wherein the position of the coupling point is changed for each product and the product is moved to an optimum inventory base by monitoring the required lead time which changes depending on the change in demand, market trend and supply capacity. The described integrated management method for commercial products. 3. The inventory scattered at the actual multi-stage / plurality of bases is converted into one virtual base of stock based on the delivery lead time and the stock amount, and the cup is converted based on the converted value. The inventory management method according to claim 2, wherein the inventory is allocated at a ring point. 4. The production capacity of a plurality of actual production bases is converted into one logical virtual production base based on the manufacturing lead time and the delivery lead time, and the product is missing at the coupling point. 4. The method for integrated management of products for sale according to claim 3, wherein a schedule plan is prepared. 5. The method for integrated management of sales of goods according to claim 4, wherein an instruction is given to allocate the inventory of one logically virtual inventory base to a plurality of existing physical bases. 6. The integrated production and sales management method according to claim 5, wherein the production request ordered to one logically virtual production site is instructed to be distributed to a plurality of existing production sites. . 7. The setting of the coupling point is performed by calculating a cost minimum by simulation and determining an optimal inventory position and inventory distribution in a multi-stage structure for each individual item. Item 1 integrated management method for live products.