JPH1011502A - Production plan evaluation system - Google Patents

Abstract

(57) [Summary] [PROBLEMS] To simulate a shortage situation of parts synchronized with a small schedule plan and evaluate the small schedule plan. [MEANS FOR SOLVING PROBLEMS] Step 1 of obtaining a part inventory quantity, a part quantity such as a delivery quantity and a delivery date, and a product shipment plan from a material management system;
Step 2 of creating a small-schedule plan of the line from the parts information and, for example, from a stock part quantity and a scheduled delivery date for 10 days, assigning stock parts as product use parts in the order of production schedule on the small-schedule plan; Step 3 of executing the simulation, Step 4 of displaying the result obtained by the simulation, Step 5 of determining whether or not production based on the small schedule is possible, and if possible (YES), small schedule of the line A step 6 for adjusting the delivery date and parts in accordance with the plan, and a step 7 for correcting the small-schedule plan if impossible (NO).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management technique, and more particularly, to a production plan evaluation system for simulating and evaluating a shortage situation in a small schedule plan.

[0002]

2. Description of the Related Art Conventionally, when a product is produced in a factory, a necessary small schedule plan according to the situation of the production line of the factory is created from a large schedule plan created in accordance with the shipping date of the product. Parts, people, tools, etc. are put into the production line based on the small schedule plan to produce products.

[0003] The above-mentioned small-schedule plan created in consideration of the operation status of the production line and the stock of parts usually needs to be corrected due to a shortage situation that occurs due to a delay in delivery of parts to be delivered. It is. Parts a1, a2 and a
The small schedule plan for producing 100 products A constituted by the three items will be specifically described with reference to FIG. First, in the first example, as shown in FIG. 4, the parts are delivered according to schedule, and the inventory number of the component a1 on the scheduled production start date is nine.
0 pieces, 10 backorders, and 100 parts a2 in stock
It is assumed that the number of order backlogs is 0, the number of components a3 in stock is 60, and the number of order backlogs is 40. By implementing this production plan, it is possible to produce 60 products A. In addition, the number of in-process products (products with insufficient a3) of product A is 3
You can do zero. Here, as another example, if only 50 parts a1 are delivered by the production start date and the number of parts a1 in stock is 50 pieces, then only 50 pieces of product A can be manufactured. The number of hanging products is 50 pieces. As another example, if the production start date is delayed by two days,
For example, the order backlog of the component a3 is delivered in the last two days, and the stock increases from 60 to 100. Therefore, 90 products A can be manufactured, and the number of products in process is 1
It becomes zero. Normally, as shown in the above examples,
Revise the production plan, such as urging undelivered parts, confirming the delivery date, delaying the production schedule, or changing the schedule of product production, so as to reduce the work-in-progress while checking the delivery status of parts. To implement the most convenient plan.

In practice, there is a material management system of a purchasing department for managing the ordering of parts and the like. The material management system uses a large schedule to order and deliver parts based on a rough part delivery time for each product. Managing.

[0005] By the way, when the production management department of the conventional factory implements the production plan, the delivery schedule, the parts to be delivered, the stock status, and the like are grasped by referring to the output list of the material management system, and as described above, the small schedule planning is performed. (Production plan) was revised.

However, the contents of the output list are rough based on the large schedule, and the schedule is not always synchronized with the small schedule used for actual production. Usually, it often includes an error of about one week. Therefore, if the production management department of the factory issues a material output instruction based on the output list, parts may be output before the execution date of the small schedule plan. Therefore, for example, when packing materials used in a later stage of the production process are delivered at the beginning of the process, there is a problem such as blockage of a place, and a required number of parts (missing parts) are output. There is a problem that the designation of the material causes the stock of the work-in-progress to occur, and furthermore, it is difficult to grasp the missing parts expected at the time of creating the small schedule plan.

[0007]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and simulates a situation in which parts are out of stock in synchronization with a small schedule. It is an object of the present invention to provide a production plan evaluation system configured to determine whether to modify a plan.

[0008]

In order to achieve the above object, in order to achieve the above object, an inventory data section for storing inventory data of parts, a delivery date data section for storing delivery date management data of parts, and a parts configuration table data for each product. A parts list data part to store, a shipping plan data part to store product shipping plan data, and a simulation execution part for calculating the number of missing parts for each production day based on the number of parts in stock, the number of deliveries, the number of remaining orders and the number of reserves, A small-schedule creating unit that creates a small-schedule plan based on the product shipment plan and the operation status of the line; a determining unit that determines whether to execute the small-schedule plan based on the calculated number of missing parts and a required standard; and a simulation result. , A memory unit for storing a program describing the algorithm of the system operation and the required reference, and a control unit for controlling each unit. The shortage simulations carried out daily schedule was to determine whether or directly run to correct the small scheduling by the situation of shortage parts.

A first step of preparing a small schedule describing a production schedule based on the large schedule of the material management system, and acquiring the number of stock parts and the scheduled delivery date for a required period from the material management system Then, a second step of associating the product with the number of missing parts and the scheduled delivery date by assigning stock parts to each product on the small-schedule plan, and a missing part associated with the second step A third step of displaying the number of items and the expected delivery date, and a fourth step of determining whether to correct the small-schedule plan or leave the small-schedule plan unchanged from the status of the displayed missing parts. It consisted of.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS With the above configuration, the number of missing parts, the scheduled delivery date, and the product shipping date are acquired from the material management system for a required period, and the products are ordered in the production schedule in the small schedule plan. By associating the product with the number of missing parts, the number of remaining parts, and the expected delivery date for each day of the required period, the number of missing parts and the part rank of the missing parts Then, it is determined whether or not the production schedule is appropriate.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A production plan evaluation system according to the present invention will be described below in detail with reference to the drawings. FIG. 1 is a block diagram showing an embodiment of a production plan evaluation system according to the present invention. 1 stores part inventory data, for example, RAM
(Random Access Memory). 2 stores delivery date management data of parts, for example, R
This is a delivery date data section configured by AM. Reference numeral 3 denotes a parts bill data section configured to store parts bill data of a product, for example, a RAM. 4 is, for example, 1 after the production start date.
A simulation execution unit that calculates the number of missing parts for each production day based on the number of stocks, the number of deliveries, the number of remaining orders, and the number of reserves in 0 days. Reference numeral 5 denotes a small schedule creation unit that creates a small schedule based on the product shipment plan and the operation status of the line. Reference numeral 6 denotes a determination unit that determines whether or not to execute the small-schedule plan based on the calculated number of missing parts and a required standard. 7
Is a display unit that displays a simulation result, for example, a display such as a personal computer. A memory unit 8 stores a program describing an algorithm of a system operation and the required standard. A control unit 9 controls each unit. Reference numeral 10 denotes a shipment plan data section for storing required data of a product shipment plan obtained from the material management system, for example, a product shipment date.

FIG. 2 is a flowchart showing the operation of the embodiment of the production plan evaluation system according to the present invention. The production plan evaluation operation of the production plan evaluation system according to the present invention will be described with reference to this flowchart and FIG. In the production plan evaluation system, step 1 (STP1) is to calculate the parts information such as the number of parts, the number of parts delivered, the delivery date, etc., Obtained and stored in the inventory data section 1, the delivery date data section 2, and the shipment plan data section 10, respectively. In step 2 (STP2), the small schedule creation unit 5 creates a small schedule plan for production on the factory line based on the operation status of the production line, the component information, the product shipping date, and the like. Step 3 (STP3)
Is the simulation execution unit 4 and the inventory data unit 1
After the production start date stored in the delivery date data unit 2, for example, based on the number of stock parts per 10 days, the scheduled delivery date, the product shipping date, etc., in the order of the production schedule in the small schedule plan,
The stock parts are allocated to the parts used for product production in the parts table data part 3, and as a result, the stock shortage state is clarified by associating the so-called number of missing parts and the expected delivery date with the product with a shortage of stock parts (simulation). Run).

Step 4 (STP4) is the same as step 3
The display unit 8 displays the product obtained by the simulation of (STP3), the associated missing parts, the number thereof, and the scheduled delivery date. In step 5 (STP5), the determination unit 6 determines, for example, the number of missing parts, the component rank stored in the memory unit 7 indicating the importance of the same missing part in the production process, and the allowable number of missing parts. It is determined whether or not production based on the small schedule plan in step 2 is possible. For example, if the part L has a shortage of 30 parts on the scheduled assembly date, the part L has a low part rank indicating the importance, and if the allowable number of missing parts is 100, the determination unit 6 can produce. Judge. Then, in practice, when the part L is delivered later, post-assembly is performed to deal with it. If it is possible in step 5 (YES), step 6
In (STP6), the small-schedule creating unit 5 adjusts the delivery date and parts according to the small-schedule plan of the line. If it is impossible (NO) in step 5, step 7 (STP7) executes the small schedule plan in step 2 by the small schedule creation unit 5, for example,
Modify the production order of products, delay production start date, etc.

The operation of the out-of-stock simulation of the production plan evaluation system according to the present invention will be described with reference to FIG. FIG. 3 is a diagram showing a simulation result of a stockout situation based on the small schedule plan of the production plan evaluation system according to the present invention. FIG. 3A shows a display screen of the plan 1 and a display screen of a simulation result in the plan 1.
This will be described in detail. Plan 1 is June 1 when 200 and 400 products A and B are manufactured in this order.
A small schedule plan for 10 days from the production start date of the day is shown in a line table format. Further, the simulation result represents the shortage / required number and the scheduled delivery date by allocating stock for the required number of components of the product A to be produced first.
Note that the shortage / required number of the product B and the expected delivery date are sequentially displayed on the next page and thereafter (not shown).

According to the simulation results, the stockout situation is "0" for part a1, "50" for a2, and "a3" as of June 1.
Is “150”. However, a2 indicates that the delivery is scheduled for June 9, and a3 indicates that the delivery is not scheduled within 10 days. Therefore, based on the shortage situation of this plan 1, for example, 6
In order to start the production on the 1st of the month and finish on the 4th of June, it is easily understood that the parts a2 and a3 are insufficient as described above.

FIG. 3B shows a display screen of the plan 2 and a display screen of a simulation result in the plan 2. This will be described in detail. The plan 2 is for manufacturing 400 and 200 products B and A in this order, respectively.
The small schedule plan for 10 days from the production start date of the first month is shown in a line table format. In addition, the simulation result represents the shortage / required number and the scheduled delivery date by allocating stock for the required number of components of the product B to be produced first. In addition, the shortage / required number of the product A and the expected delivery date are sequentially displayed on the subsequent pages (not shown). From the simulation results, the shortage situation is as of June 1 for parts b
1 is “0”, b2 is “20”, and b3 is “100”. However, b2 indicates that the delivery is scheduled for June 5, and b3 indicates that the delivery is scheduled for June 1.

Therefore, in order to start the production from June 1 and finish on June 9 based on the simulation of the shortage situation of the plan 2, there is a shortage at the beginning, but the above-mentioned during the production period. As described above, the shortage will be resolved, and it can be seen that there is almost no problem in the production according to the plan 2. Note that the production plan evaluation system according to the present invention can be constructed on a personal computer or a workstation by developing software for realizing the above-described operation algorithm. A small schedule plan is created, the shortage status is simulated for each production day, displayed on a display, and it is determined whether or not production is possible with the small schedule plan. Also, by setting a part rank indicating the importance of parts for assembling a product, and storing the part rank in the memory unit 7 as a comparison table with the permissible number of missing parts, it is possible to determine whether parts are missing. It may also be possible to determine whether or not production is possible. Also, as described above, the simulation period for grasping the out-of-stock condition is appropriately from one week to 10 days from experience.

[0018]

As described above, the present invention simulates the shortage situation of parts synchronized with the small schedule plan, and determines whether to perform the production according to the small schedule plan or to modify the small schedule plan. Thus, a production plan evaluation system is provided. Therefore, the production management department of the factory can easily evaluate the small schedule plan using the production plan evaluation system according to the present invention. Further, there is an effect that it is possible to issue a material output instruction in accordance with actual production based on the modified small schedule plan.

Further, by issuing a command to output materials based on the modified small schedule plan so as to prevent the occurrence of missing parts, there is a great effect that the stock of in-process products can be eliminated.

Further, since the simulation result of the out-of-stock situation is displayed on the screen of a personal computer or the like in an easy-to-understand manner, it is easy to grasp the out-of-stock parts and to easily manage the parts.

[Brief description of the drawings]

FIG. 1 is a block diagram showing an embodiment of a production plan evaluation system according to the present invention.

FIG. 2 is a flowchart showing an operation of the embodiment of the production plan evaluation system according to the present invention.

FIG. 3 is a diagram showing a simulation result of a stockout situation based on a small schedule in the production plan evaluation system according to the present invention.

FIG. 4 is a diagram showing the relationship between the required number of component parts of a product and inventory.

[Explanation of symbols]

 Reference Signs List 1 stock data part 2 delivery date data part 3 parts list data part 4 simulation execution part 5 small schedule creation part 6 judgment part 7 display part 8 memory part 9 control part 10 shipping plan data part

Claims (10)

[Claims] 1. An inventory data section for storing parts inventory data, a delivery date data section for storing delivery date management data for parts, a parts table data section for storing parts configuration table data for each product, and product shipping plan data. And a simulation execution unit that calculates the number of missing parts for each production day based on the number of parts in stock, the number of deliveries, the number of remaining orders and the number of reserves, and a small schedule based on the product shipment plan and line operation status A small-schedule creating unit for creating a plan, a determining unit for determining whether to execute the small-schedule plan based on the calculated number of missing parts and a required standard, a display unit for displaying a simulation result, and an algorithm of a system operation. A memory unit for storing the described program and the required standard, and a control unit for controlling each unit, and a shortage simulation is performed for each day of the small schedule. Applied, production planning evaluation system so as to determine whether to perform either or as it is modifying the small scheduling by the situation of shortage parts. 2. The production plan evaluation system according to claim 1, wherein said required standard is constituted by a part rank and an allowable number of missing parts. 3. The production plan evaluation system according to claim 1, wherein the rank and the number of missing parts for each part are stored in a memory as a comparison table. 4. The inventory data section, a delivery date data section,
2. The production plan evaluation system according to claim 1, wherein the parts table data section and the shipping plan data section are configured by a RAM. 5. A first step of preparing a small schedule describing a production schedule based on a large schedule of the material management system, and acquiring the number of stock parts and a scheduled delivery date for a required period from the material management system. Then, a second step of associating the product with the number of missing parts and the scheduled delivery date by assigning stock parts to each product on the small-schedule plan, and a missing part associated with the second step A third step of displaying the number of items and the expected delivery date, and a fourth step of determining whether to correct the small-schedule plan or leave the small-schedule plan unchanged from the status of the displayed missing parts. A production plan evaluation system composed of 6. The production plan evaluation system according to claim 5, wherein when allocating the inventory parts for each product, the inventory parts are allocated to the component parts of the product in order from the earliest production schedule. 7. The production plan evaluation system according to claim 5, wherein said small schedule plan is represented in a line table format. 8. The production plan evaluation system according to claim 5, wherein for each of the plurality of small schedule plans, a missing part of a product is associated with a number and a scheduled delivery date. 9. The production plan evaluation system according to claim 5, wherein said display is displayed on a terminal display. 10. The production plan evaluation system according to claim 5, wherein said required period is approximately 10 days.