JP2003150223A - Production plan preparing method and system therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce any influence due to the delay of a term of delivery, and to prepare a production plan of highly practical use. SOLUTION: This method comprises a process for reading plan materials including the information of at least one bottle neck process, a process for preparing an overall production plan model based on the read plan materials, a process for extracting only information related with the bottle neck process from the overall production plan model, a process for preparing a bottle neck model constituted of only the bottle neck process based on the information related with the extracted bottle neck process and the overall production plan model, and a process for preparing an optimized production plan for deciding production from production demand by executing overall optimization with respect to the bottle neck model.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and system for producing a product production schedule. In this specification, "plan material" means order information, sales plan,
Item information, parts list, production capacity information, inventory / order remaining information,
Refers to master data that is generally used to create a production plan, such as an existing production plan or a process chart that includes movement of products.

A "bottleneck process" is a process that is difficult to adjust when a production plan needs to be changed.
“Product” means an independent demand item such as a product or service part for which a demand is generated by a customer's request, or a product or service part for which a demand is generated for a part required to produce an independent demand item. Dependent demand items such as. "Production plan" refers to determining the production amount for each product for each production site from the production demand for each product for each production site. Products and parts are collectively referred to as "items".

[0003]

2. Description of the Related Art In the manufacturing industry, based on the sales prospects of products and the orders from customers, the production demand amount for each production base (production data, delivery date information, quantity, etc. required for production planning) ) Is created and contacted to the production base. At the production base, the production demand is received as an order, and a production plan is created in consideration of the facilities and people's abilities, parts inventory, and order backlog. The production planning system aims to create a production plan for a single process or a single production site that performs production for an order. Creating a production plan means, for example, in a factory,
This is production planning of a product assembly process for a customer order, and production processing of a component assembly process is performed for an order of parts from a factory in outsourcing.

[0004]

[Problems to be Solved by the Invention] There are problems such as delay of information due to orders moving between production bases, creation of inexecutable plan due to lack of consideration of production restrictions of the customer, and delay of delivery due to this. As a result, the entire planning cycle becomes longer, making it difficult to flexibly respond to demand fluctuations. In order to solve the problem that occurs when this order moves between production bases, JP-A-2000-246598
The gazette describes a decentralized integrated production support system that digitizes request-side orders and supply-side responses to them, synchronizes information on production activities among multiple production sites, and improves productivity. ing. With such a system, it is possible to reduce redundant work between production bases, improve productivity, and improve planning accuracy. Furthermore, it is possible to accurately and optimally convey the order of the requesting side to the supplying side, and based on this, the supplying side can create a production plan.

However, the order to the supply side is generated from the production plan of the request side, and it is not intended to simultaneously create the production plan in consideration of the production restrictions of the supply side and the supply side. Therefore, there is a possibility that problems such as the creation of an inexecutable plan and the delay in delivery due to the lack of consideration of the production restrictions of the customer.

In recent years, it has been required to reduce the total lead time from the procurement of parts to the delivery to the customer through several assembly steps. The need to create a production plan considering all production activities is increasing, and an optimal production planning method aiming at overall optimization is drawing attention. The use of the optimal production planning method has the following advantages. (1) By defining the entire production bases in which production activities are related to each other as one model, the visibility of the whole can be improved and problems can be grasped at the initial stage of the plan, which enables quick countermeasures.
(2) At the same time, the total lead time can be shortened because a plan that considers the production constraints of all production sites can be created in parallel. As a result, demand fluctuations can be swiftly absorbed, and effects such as improvement of the delivery date compliance rate and optimization of inventory can be obtained by creating a feasible plan throughout.

As an optimum production planning method, generally, many methods using mathematical programming have been reported. Japanese Patent Laid-Open No. 8-
As described in Japanese Patent No. 305763, an optimal production planning method is applied after a regular initial schedule, and as described in Japanese Patent Laid-Open No. 5-108649, multiple initial schedules are prepared and the optimum one is selected from them. A production planning system to which an optimum production planning method is applied, such as creating a different production plan, is also considered.

However, the overall optimum production plan can be achieved by centrally managing the planning materials of all production bases, and one production base can create an optimum production plan in consideration of the production restrictions of all the production bases. However, maintenance work becomes enormous because it takes time to change the production planning model that changes from moment to moment.

If an optimized production planning system is provided at each production site and a production plan is created within each site, maintenance work can be localized and the amount of work is small, and no change time is required. However, since an order that is input data for creating an optimum production plan is generated between the bases, there remains a problem that the total lead time, which has been delayed, becomes long.

When master data such as affiliated companies can be managed at one site, the master data of all sites can be integrated to create a production planning model. Therefore,
It is also possible to create a production plan that simultaneously considers the production constraints of all production bases. However, if the production activities are not related to each other but the production activities are related to each other, the master data does not exist in one base, and thus it is possible to create a production plan for each base in consideration of production constraints within a single base. However, in many cases, it is not possible to create a production plan that considers the production constraints of all the sites. An object of the present invention is to reduce the influence of delay in delivery time and the like and create a highly feasible production plan.

[0011]

According to one aspect of the present invention, a step of reading out a planning material including information on at least one bottleneck step, and an entire production planning model based on the read-out planning material And a step of extracting only information about the bottleneck process from the overall production planning model, based on the extracted information about the bottleneck process and the overall production planning model, the bottleneck process Production including a step of creating a bottleneck model consisting only of the above, and a step of creating an optimized production plan for determining the production amount from the production demand by performing overall optimization on the bottleneck model A planning method is provided.

The bottleneck model is preferably created so as to inherit the flow of steps in the overall production planning model. It is preferable that the global optimization is performed so as to produce the production demand as much as possible with respect to the bottleneck model.

According to another aspect of the present invention, there is provided a production plan creating method for producing production plans of all the sites while linking the production planning systems of a plurality of associated sites.
At least one first site having a production plan creating means for creating a production plan by overall optimization based on a production plan model created based on planning materials includes information on at least one first bottleneck process. The first planning material is read, a first production planning model for the entire first base is created based on the read first planning material, and the first bottleneck process is performed from the entire first production planning model. Extracting only information and creating a first bottleneck model consisting of only the first bottleneck process based on the extracted first bottleneck process and the overall first production planning model; At least one second site that does not have a planning model reads and reads the second planning material including the information of at least one second bottleneck process. A second production planning model for the entire second base is created based on the second planned material, and only the information on the second bottleneck process is extracted from the overall second production planning model, and the extracted Based on the second bottleneck process and the overall second production planning model,
Creating a second bottleneck model consisting only of the second bottleneck process, and sending the second bottleneck model from the second site to the first site according to the request of the first site. , At the first base, connecting the first bottleneck model and the second bottleneck model, and creating an integrated bottleneck model integrating the first bottleneck model and the second bottleneck model, A method of creating a production plan including a step of creating an optimized production plan for determining a production amount from a production demand amount by performing overall optimization on the integrated bottleneck model. By performing global optimization on the integrated bottleneck model,
And a step of creating an optimized production plan for determining the production amount from the production demand amount.

It is preferable that the bottleneck model is created so as to inherit the flow of steps in the overall production planning model. It is preferable that the global optimization is performed so as to produce the production demand as much as possible with respect to the bottleneck model.

According to another aspect of the present invention, there is provided a production plan creating method for creating production plans for all the sites while linking the production planning systems of a plurality of associated sites, which are created based on planning materials. At least one first base having a production plan creation means for creating a production plan by overall optimization based on the production planning model described above, at least one first bottleneck process information, effective production start date and effective production end The first planning material including a fixed period between the first and second days is read, and the first planning material is read based on the read first planning material.
A first production planning model for the entire base is created, and only the information relating to the first bottleneck process is extracted from the overall first production planning model, and the extracted first bottleneck process and the first production for the entire production process. At least one second base including a step of creating a first bottleneck model consisting of only the first bottleneck process based on a planning model and a second base including at least one base not having the production plan creation model A second planned material including information on the second bottleneck process is read, and a second production planning model for the entire second base is created based on the read second planned material.
Only the information related to the second bottleneck process is extracted from the overall second production planning model, and the extracted second
A step of creating a second bottleneck model consisting of only the second bottleneck step based on the bottleneck step and the second production plan model of the whole; Sending the second bottleneck model to a first base; and connecting the first bottleneck model and the second bottleneck model at the first base to connect the first bottleneck model and the first bottleneck model A process of creating a production plan for determining a production amount from a production demand amount by creating an integrated bottleneck model that integrates the two bottleneck models and performing overall optimization on the integrated bottleneck model. , When the planned completion date of the production plan is within the fixed period, the production plan is fixed, and the production plan has a relationship with allocation. The process of determining the production plan, issuing the production plan together with the allocation and issuing the order, and dividing the production plan into the production plans required by each production site A production planning method including a sending step is provided.

The bottleneck model is preferably created so as to take over the flow of steps in the overall production planning model. It is preferable that the global optimization is performed so as to produce the production demand as much as possible with respect to the bottleneck model.

According to still another aspect of the present invention, at least one first base having a production plan creating means for creating a production plan by overall optimization based on a production plan model created based on planning materials. And a second base including at least one base that does not have the production plan creation model, the production planning system for all bases is linked with the production planning systems of a plurality of associated bases. A plan creation system, which is provided at the first base,
First storage means for storing a first planned material including information on at least one first bottleneck process, and the first based on the first planned material read from the first storage means.
A first production planning model for the entire base is created, and only the information relating to the first bottleneck process is extracted from the overall first production planning model, and the extracted first bottleneck process and the first production for the entire production process. A first processing means for creating a first bottleneck model consisting of only the first bottleneck process based on a plan model; and a second processing unit provided at the second base and including at least one second bottleneck process
Second storage means for storing the planned material, and a second production planning model for the entire second base based on the second planned material read from the second storage means,
Second information consisting of only the second bottleneck process, based on the extracted second bottleneck process and the overall second production planning model, by extracting only information related to the second bottleneck process from the production planning model; Second processing means for creating a bottleneck model, and the second bottleneck model provided for each of the first and second bases from the second base to the first base according to a request from the first base. And a first transmitting / receiving means for transmitting the first bottleneck model and the second bottleneck model, the first bottleneck model and the second bottleneck model being connected to each other at the first point.
By creating an integrated bottleneck model that integrates the bottleneck model and the second bottleneck model, and performing overall optimization on the integrated bottleneck model, optimization for determining the production amount from the production request amount is performed. And an optimized production plan creating means for creating a production plan, and the optimized production plan provided in the first base is divided into production plans required by the second bases. And a second transmission / reception means for sending to the production planning system.

Further, in a production plan creation system for producing production plans for all the sites while linking production plan systems at a plurality of sites, the overall optimization is performed based on the production plan model created based on the planning material. At least one first site having a production plan creating means for creating a production plan reads out a first planned material including information of at least one first bottleneck process, and based on the read first planned material. A first production planning model for the entire first base is created, only information regarding the first bottleneck process is extracted from the overall first production planning model, and the extracted first bottleneck process and the entire A procedure for creating a first bottleneck model consisting of only the first bottleneck process based on the first production planning model; A second site including at least one site that does not have a read out second plan material including at least one second bottleneck process information, and the second plan material based on the read second plan material. Second of all bases
A production planning model is created, and only information regarding the second bottleneck process is extracted from the overall second production planning model, and based on the extracted second bottleneck process and the overall second production planning model. , A procedure for creating a second bottleneck model consisting only of the second bottleneck process, and a procedure for sending the second bottleneck model from the second location to the first location according to the request from the first location And, at the first site, connects the first bottleneck model and the second bottleneck model, and creates an integrated bottleneck model that integrates the first bottleneck model and the second bottleneck model. , By performing overall optimization on the integrated bottleneck model, an optimized production plan for determining production volume from production demand For causing a computer to execute a procedure for performing the production and a procedure for dividing the optimized production plan into a production plan required by each of the second bases and sending the production plan from the first base to each base The program is provided.

It is preferable that the bottleneck model is created so as to inherit the flow of steps in the overall production planning model. It is preferable that the global optimization is performed so as to produce the production demand as much as possible with respect to the bottleneck model.

According to the production planning technique described above,
Since the global optimization is performed on the integrated bottleneck model formed only by the bottleneck process, it is possible to reduce the amount of work required for the optimization.

[0021]

DESCRIPTION OF THE PREFERRED EMBODIMENTS First, the consideration made by the inventor will be described with reference to FIG. FIG. 1 is a block diagram showing an example of a system configuration of a production plan creating system according to an embodiment of the present invention.

The production plan creation system shown in FIG. 1 creates production plans for all sites by linking the production plan systems of a plurality of associated production sites. The plurality of production bases are connected by, for example, a communication network. The production plan creation means 103 for creating a production plan model from the planning material 108 necessary for creating the production plan is arranged at at least one production site. Instead of a production base,
A newly added planning agent base may be placed for the purpose of acting as a production planning agent.

The production planning base collects data on the bottleneck process and data on products manufactured in the bottleneck process from the production planning model created by each production base via the network. Create a production planning model for all production sites from the collected data. A production plan is created from the created production plan model. The created production plan is decomposed into a production plan required by each site and transmitted to each production site.

Here, the data concerning the bottleneck process collected from each production site 102 by the production planning base 101 is at least one production process among all the production processes in the production site, and the capacity usage of this production process. It includes a possible quantity, a product to be produced in this production process, its working amount, a period required for production, and a production process sequence. In addition, based on the data collected by the production planning base 101 from each production base 102 via the network, all the production bases 10
When assembling the production planning models 1, 102, the item codes common to all the production bases 101, 102 are used to identify the items of the production bases 101, 102 and relate the items between the production bases. By carrying out the above steps, it will be possible to create a production plan for all production sites.

Based on the above consideration, embodiments of the present invention will be described below with reference to the drawings. Specifically, a production planning method of a personal computer (hereinafter referred to as a personal computer) will be described as an example.

2 and 3 are views showing the contents of the planned material. The planning material 108 (FIG. 1) is generally called master data and is a planning material that is a basis for creating a production plan. The item master 201 is an item code (item) or name (item name) of a product or part that is a target of a production plan and accompanying information, for example, a manager (construction worker) of the item or an expiration date of the item. Consists of. Parts table 202
Is a product or product semi-finished product and the parent-child relationship between the items, and the number of child items used when the parent item is produced. The process chart 203 is a process name that can identify a process code (process), a manufacturing process such as a line or a cell, or a storage process such as a product warehouse or a parts warehouse, and if the manufacturing process is a manufacturing process included in the process. It refers to calendar information that expresses available capacity (for example, line operation time in a day for line production, regular work time in cell production, also called process capacity) and operation days / non-operation days, which are capacity constraints. It consists of code etc.

The supply source information 204 is a production process that represents a producible item and a place where the producible item is produced, a work amount that represents a work time used to produce one unit of the producible item,
And the lead time (hereinafter,
It is referred to as "LT". ) Consists of. The supply master 205 is
It defines the movement of items between processes. The target item, the source process that sends the produced target item, the destination process that uses the shipped target item, and the supply lead time (movement time). Hereinafter, this is referred to as "supply LT".)
And defines the order of operations in the production planning model.

The model information 301 includes a model name (model name) which is a unit for placing an order which is a source of a production request, a product belonging to the model, and an expiration date when the relationship between the model and the product is valid. The shipping plan 302 is a model production request, and is information that is the basis of the production plan. It consists of model, shipping process, requested date, and requested quantity. In order to meet this production requirement, what decides “when, what, where, and how many will be produced” is the production plan. Neck process 30
3 defines a bottleneck, and defines at least one process such that the production amount in the neck process determines the production amount in all processes. In addition, a production pattern that indicates the production sequence of products, such as when multiple products can be produced (in the case of line production, in order to reduce setup changes, continuous production that produces the same product continuously and the production cycle should be shortened. In order to improve the ability to respond to fluctuations in demand, multiple products are produced every day in the same quantity (equal production).

Further, the neck process 303 not only satisfies the production capacity constraint of the process defined as the neck process, but also simultaneously considers the production capacity constraint of the upstream process (hereinafter referred to as "lower process") before it. It has a lower process check flag indicating that the process is to be performed, and a required lead time of a component from the lower process (hereinafter, referred to as “request LT”). The following process check flag is set when the used part of the item produced in the neck process is, for example, an item to be ordered from the subcontractor, and the supply LT from the subcontractor is set as the request LT together with this. The production plan will be created so as to satisfy the production capacity constraint of the neck process.

The priority 304 is an optimization condition for designating which product is preferentially produced when the production capacity constraint cannot be satisfied. It consists of priority for each neck process and each item. The calendar 305 is working day information given to the process, and is composed of a date and a flag indicating a working day / non-working day. For example, if the flag specified by the date is 1, it is treated as a working day, and if 0, it is treated as a non-working day. Ability information 30
6 includes information on the available capacity (usable time) that is the production capacity constraint and the period for which the capacity is held. By defining the calendar code and the capability code defined by the calendar 305 and the capability information 306 in the process chart 203, it is possible to express the working days and usable capacities of each process.

Next, a method of creating a production planning model from planning materials will be described with reference to FIGS. 4 to 7. FIG. 4 shows a product configuration of a personal computer (hereinafter referred to as “personal computer”). In the example of this product configuration, two types of personal computers, a desktop and a notebook, are produced. There are two types of desktop, a tower type and an integrated type, and one type of notebook. The shipping request is specified by the desktop and the notebook, and the product production plan is created in three types: tower type, integrated type, and notebook type.
In other words, desktop shipment requests are prorated by the tower type and the integrated type.

In order to create the production plan, the layers of "tower type, integrated type, notebook type" and the following layers in the product configuration shown in FIG. 4 are used. The layers above "Tower, Integrated, Notebook" are just product categories and are not needed for production. In the present embodiment, the category “desktop, notebook” generally refers to a product group,
It is called a model, etc., and the categories of "tower type, integrated type, notebook type" are often called "product", "product type", "product type name", etc. Hereinafter, the product designation when creating the shipping request will be referred to as “model”, and the product designation when creating the production plan will be referred to as “product”.

The tower type is a case 1, a board 1,
The accessory 1 is used, and the board 1 uses a CPU and a memory as parts. Each unit uses one unit for each tower type personal computer. Similarly for the integrated type and the notebook type, the amount of parts used per unit is one unit. Only the substrate 2 uses 2 units of memory per unit. Generally, there are several tens or more parts of a personal computer, but in this embodiment, five kinds of parts are described for each product for simplicity. Hereinafter, manufacturing of a notebook computer will be described.

FIG. 5 shows the supplier information 501 and the supply master 5 regarding the notebook computer in the product configuration shown in FIG.
02 is specifically shown. FIG. 6 shows a part of a notebook computer production planning model created based on the supplier information 501 and the supply master 502 of FIG.
The product assembly 601 and the parts warehouse 602 indicate the processes defined in the process chart. Supplier information 501 (Shopl, PC-
3038, 1, 10) and (SOKO, B-3038-
3, 0, 0) are the product assembly 601 and the parts warehouse 6 respectively.
02 (production process, producible item, LT, work amount), and supply master 502 (Shopl, PC-303
8, 3, 0) is information on the movement of the item (B-3080-3) from the parts warehouse (SOKO) to the product assembly (Shopl), and the item B-3038-3 (board 3) is moved from the parts warehouse. It indicates that the product is shipped and delivered to the product assembly (process), and the supply LT at that time is “0”.

From this information, a part of the production planning model shown in FIG. 6 can be created. Similarly, when a production plan model of a notebook computer is created, it becomes as shown in FIG. The product configuration of the notebook computer includes parts such as a housing 3, an accessory 3, and a CPU. It can be assembled as a production planning model in the same manner.

A method of editing (compressing) the production planning model shown in FIG. 6 into a model including only a neck process will be described with reference to FIGS. 8 to 10.

As shown in the neck process 303 in FIG. 3, product assembly and component assembly are set as the neck process. Based on this, among the relationships among all the processes (product assembly, component warehouse, component assembly, component vendor) shown in FIG. 8, only the relationship of processes (product assembly, component assembly) consisting of only the neck process was considered (extracted). A production planning model (hereinafter referred to as a bottleneck model) is created.

FIG. 9 shows a bottleneck model created by extracting only the bottleneck process from the production plan model of the entire notebook computer shown in FIG. At this time, the supplier information of the product assembly and the parts assembly is not changed. That is, the information from the production planning model of the entire notebook computer shown in FIG. 7 is taken over. At this time, in creating the bottleneck model, the parts warehouse located between the product assembly and the parts assembly is removed. Therefore, it is necessary to edit the supply master, which is the information related to the movement of the base 3 from the parts assembly to the product assembly. The relevant information is the manufacturing LT and supply LT 701, 702, 703 relating to the base 3 of FIG.
Is. When these LTs are summed up, the supply LT from the component assembly of the base 3 to the product assembly is "1". If the supply LT from the parts warehouse to the product assembly is "2", the supply LT from the parts assembly to the product assembly is "3".

As shown in FIG. 10, when the creation (assembly) of the bottleneck model is completed, a new parts table 1001 regarding the bottleneck model, supplier information 1002, and a supply master 1003 can be created. The parts table 1001, the supply source information 1002, and the supply master 1003 have the same format as the supply source information and the supply master described in the method of creating the production plan model of the entire notebook computer. Therefore, it is also possible to create the bottleneck model shown in FIG. 9 from the parts table 1001, the supply source information 1002, and the supply master 1003. A production plan is created based on the production planning model (bottleneck model) consisting of only the bottleneck process created by the above process.
An example of a method of creating such a production plan will be described with reference to FIGS. 11 and 12.

The shipping plan read as the planning material is generally a name when a product order from a customer or a part order from a parent company to a subsidiary is considered as a production request to each production site. For example, if there is an order for a notebook personal computer PC-3038, this is read as a shipping plan. Request date and request amount are 2 for 14 days each
500 units, 5200 units on 21st. In the present embodiment, it is assumed that there is a shipping plan on weekends and the production period allowed for one shipping plan is one week.

The content indicated by reference numeral 1201 in FIG. 12A is the production plan in the product assembly process created based on the shipping plan. The usable capacity of the product assembly process from the 8th to the 12th (first week) is 5000 / day. Also, 1
Since 3 and 14 days are non-working days and cannot be produced, the usable capacity is 0 / day. Similarly, the usable capacity of the product assembly process from the 15th to the 21st (the second week) is 10,000.
/ Day. Assuming that the production pattern defined in the neck process is, for example, continuous production, and a production plan is created while advancing the allowable production period,
From the 8th onwards, the production volume will be decided by packing 500 units each from the 8th. The production amount is determined to be 500 units because the daily usable capacity of the process is 5000, and it is a notebook PC-
This is because the amount of work per 3080 is 10 (example).

In the same way, in the second week, the production amount is determined by packing the 1000 units forward from the 15th. This is because, on the 20th day of the second week, as a result of advancing by 1000 units from the 15th to the 19th, the remaining 200 production units should be produced in order to satisfy the demand amount of the shipping plan.

The content indicated by reference numeral 1202 in FIG. 12B is a production plan in the component assembly process created based on the production plan in the product assembly process. Generally, in a method called optimized production planning using mathematical programming, the production amount and usable capacity of each product item of the product assembly process and the component assembly process are checked. Then, a production plan for the product assembling process and the component assembling process is created so as to satisfy the production demand amount within a range not exceeding the usable capacity of both processes. In addition to such capacity constraints, we also check material constraints such as whether or not we can procure the required number of parts at the required time to produce the product by the scheduled completion date.

FIG. 11 shows a notebook personal computer PC-308.
This is a material constraint when the scheduled completion date of 0 is 9 days. As shown in Fig. 11, LT is used in the product assembly process.
In order to assemble a product using only = 1 (the assembly will be started on the 9th and the assembly will be completed on the 9th), the supply LT = 1, so the substrate 3 will be removed from the parts assembly process on the 8th of the previous day. Move to the product assembly process, and base 3 in the parts assembly process on the 7th day before the day 3
Finished production, and LT of the base 3 in the parts assembly process = 2
Therefore, it means that production must be started on the 6th.

In the present specification, planned materials that are generally taken into consideration when creating a production plan, such as the stock quantities of products and parts and the planned storage quantities, will not be described in detail. It is the excess and deficiency and the procurement time, and the production plan is created by simultaneously considering the capacity constraint and the material constraint described above. In this way, the planned completion date and the production amount of each product for each process are determined from the shipping plan, and the production plan is created.

The production plan creation process described above will be described with reference to the flowchart of FIG. First, in step 1301, the planning material (FIGS. 2 and 3) is read. The reading destination may be a storage device such as a hard disk of a PC or a database managed by a database management system. In step 1302, a product configuration is created based on the read planning material, and an overall production planning model as shown in FIG. 7 is created using the supplier information and the supply master. The production planning model is
Since it differs depending on the production planning system, it is not limited to the tree type shown in the present embodiment. For example, a table format such as a summary parts table may be used.

Next, in step 1303, a bottleneck model is created using the information of the overall production planning model and the neck process. At this time, at least one or more bottleneck processes may be provided, and the number thereof is not limited. In step 1304, optimization calculation using mathematical programming is performed. The optimization calculation is to determine the value of a variable such that the objective function is minimized under constraint conditions such as capacity constraint and material constraint.

In the present embodiment, for example, the usable capacity per day of each process and the LT correspond to the constraint condition. The objective function is to produce as much production demand as possible. The variable is the production volume of each process, each day, and each product. These variables are determined as shown in FIG. 12 as the production amount, and these are set as the production plan.

In step 1305, the production amount of the product is output as a production plan to an output means such as a CRT or a printer, or a storage means such as a disk, a memory or a database. The example described above is an example of a production plan creation method using a single production planning system.

Thereafter, based on FIGS. 14 to 20,
A method of creating production plans for all sites by linking production planning systems at multiple sites will be described. Prior to the explanation,
The configuration of the production planning system according to the embodiment of the present invention will be described with reference to again.

As shown in FIG. 1, the production plan creation system 101 includes a planning material input means 105, a production plan model management means 104, a production plan creation means 103, a planning result output means 106, and a planning data communication means. And 107.

The planning material input means 105 uses the planning material 10
8 is read into a storage means such as a memory. The production planning model management means 104 creates and manages a production planning model using the read planning material 108. The production plan creation means 103 creates a production plan using a method such as mathematical programming based on the production plan model managed by the production plan model management means 104. The plan result output means 106 uses the production plan created by the production plan creation means 103 and the production plan model managed by the production plan model management means 104, the production plan, supplier information, the supply master, and the parts table relating to the bottleneck model. The plan result 109 is output. The plan data communication unit 107 stores the plan material, the production plan, and the plan result necessary for producing the production plan, for example, the network 110.
1 and so on. Plan data communication means 107
May be a means such as a telephone for communicating by voice.

The production planning system 102 different from the production planning system 101 is a production planning system 101.
From the production plan creating means 103. In addition, the production planning system 101 and the plurality of production planning systems 102 are connected by a network 1101 or the like.

In the present embodiment, although only one production plan creating system including the production plan creating means is shown, at least one production planning system among the production planning systems connected to the network. Should have the production plan creating means 103. Further, all the production planning systems are equipped with the production planning creation means 103, receive the production planning created by the production planning creation system 101, and use the received production planning as a constraint condition to further detail the production planning for the own site. You can make a plan. In the system having the above configuration, the production plan creation system 101 creates the production plan model by the above-described method at the timing of creating the production plan, and then creates the bottleneck model.

FIG. 18 shows a production planning model created at the bases 1 to 3. Code 1 is assigned to location 1.
A bottleneck model 801 is created. Base 1
Requests the transfer of the bottleneck model, which is the production planning model, to the production base (provisionally, base 2 and base 3) having the production planning system 102 connected to it by the network. The production planning system 102 of the bases 2 and 3 that has received the transfer request performs the process described below.

FIG. 14 is a flow chart showing the processing contents. In step 141, the site 2 receives the transfer request for the information of the production planning model. At the timing of reception, in step 142, a production planning model for itself is created. Create a bottleneck model based on the production planning model. In step 143, the bottleneck model created in step 142 is converted into production plan model data in the format of the supplier information 1808 shown in FIG. 18 at the site 23 so that the production plan creation system 101 at the site 1 can use it. Forward.

The timing of creating the bottleneck model may be the above timing, or the bottleneck model may be created in advance and the production plan creating system 1
The transfer request may be transferred when the transfer request from 01 is received.
Further, the production plan creation system 101 may request transfer at the same time as the production plan creation system 101 starts the production plan creation, or the bottleneck model creation in the production plan creation system 101. After that, the neck process configuring the bottleneck model may be referred to, and the lower process check flag may be referred to. Similarly, at the base 3, it is transferred as production plan model data in the form of supplier information 1809. As described above, the bottleneck model (data relating to the bottleneck process) collected by the production plan creation system 101 of the base 1 from the production planning systems 102 of the bases 2 and 3
Are denoted by reference numerals 1802, 1803, 1808 and 1809.

Next, a method of combining the bottleneck model collected from the production planning systems 102 of the sites 2 and 3 with the bottleneck model of the site 1 created by the production plan creating system 101 of the site 1 will be described.

In FIG. 18, the production planning system selects the neck process 1804 included in the bottleneck model of the base 1 from the lower process check flag of the neck process information 1810 of the base 1. On the other hand, the bottleneck model of the base 2 is created from the supplier information 1808 of the base 2 and the neck process 1805 is selected. FIG. 17 shows the relationship between the neck process 1804 at the site 1 and the neck process at the site 2. The parent item X produced in the neck process 1804 uses the item A as its child item. on the other hand,
In the neck process 1805, the parent item A is produced from the child item a. From this, the bottleneck model 1802 is connected to the bottleneck model 1801 (1606 in FIG. 16) so that the item A produced in the neck process 1805 is delivered to the neck process 1804, and the bottleneck model of the base 1 and the base 2 are connected. Assemble a bottleneck model that integrates the bottleneck model.

When assembling the bottleneck model, information relating to the movement of the item A from the neck process 1805 to the neck process 1804 is created as shown in the supply master 1811. The supply LT uses the demand LT set in the neck process 1804. Then, the production planning system 1
01 indicates a neck process 1 in which a lower process check flag is set from the neck process of the connected bottleneck model 1802.
Select 806. As in the case of assembling the bottleneck model described above, a bottleneck model in which the bottleneck model of the base 2 and the bottleneck model of the base 3 are integrated is assembled. By repeating this, the production planning model 1613 of all the sites as shown in FIG. 16 is assembled.

The above is an example in which the base 1 is a main base for production planning, and the bases 2 and 3 are subordinate bases. For example, a parent and child who manufacture products such as affiliated companies and parts necessary for them and are involved in mutual production activities. An example of related production sites is shown.

In another embodiment, the main base for production planning is not the production base. For example, this is a case where the main base is a production planning proxy base by a third party.
In this case, in production planning such as confidentiality agreement, each production site requests the production planning agency site to make a production plan based on a certain rule. As described above, the production plan model can be created by using the supplier information, but since the production planning is performed on behalf of a third party, the supplier process and the supplier process at different bases In many cases, the item code of the item to be moved is different.

Therefore, as shown in FIG. 21, an item mapping table is provided at the production planning agency base.
The item mapping table is, for example, item B at the site 1.
-3080-3 and the item Z-1010-101 of the base 2 are common item codes KIBAN-30 of the base 1 and the base 2.
Correspondence is established with 1. As a result, for the order of the item B-3080-3 from the base 1, at the base 2, the item Z
It would be good to produce -1010-101.

Even if the item mapping table is not provided, a common item code may be reflected in the item master, which is a planning material, as master data of each site prior to production planning. Alternatively, if there is an independent demand at each base, not only a production plan is created based on the dependent demand generated from the independent demand of the highest base on the production plan model as described above, but also transferred as production plan model data. The shipment plan, which is an independent demand, may be added to the data to be stored. If there is a material constraint in addition to the production constraint, this may be added to the production planning model data.

In this way, the production planning model 1613
If (Fig. 16) can be created, a production plan for all bases is created by using the same method as the production plan creation by the above-mentioned single production planning system, and the created production plan is transferred to each base. be able to.

FIG. 15 shows the process up to the transfer of the production plan described above. As shown in FIG. 15, in step 151, the site 1 receives the production planning model data. In order to identify which site the transmitted / received data belongs to, a site code is added to the neck process information and supplier information at the time of this reception. In step 152, the base 1 creates a production planning model for all bases from the bottleneck model received from each base. In step 153, a production plan is created for the production planning models of all the bases by using an optimization method such as mathematical programming. This production plan is divided (divided) into production plans for each site as shown in FIG. 20, and the production plan created and divided by the site 1 is transferred to each site in step 154.

FIG. 19 shows the operation of the entire system according to this embodiment. Reference numerals 1906 to 1909 represent the configuration of the production planning model at each production site. The circles that make up the production planning model represent the processes within each production site, and the black circles represent the bottleneck processes. For example, the process 1910 of the vendor's production planning model 1909 is a vendor bottleneck process. Only the information relating to the bottleneck process is collected from these production planning models to create the production planning model 1901 for all production sites. A production plan is created based on this. Since only the information related to the bottleneck model needs to be used from the planned materials at all production sites, compared to the case where all planned materials are used,
The capacity of storage devices such as disks and memories can be greatly saved, and the production planning model can be reduced, so that the amount of calculation and the calculation time associated with the production planning can be reduced.

FIG. 2 shows another embodiment according to the present invention.
It will be described with reference to FIGS. 22 to 2
As shown in FIGS. 4A to 4C, a usage pattern in which the production plan created by the production plan creation system is issued instead of issuing the order form will be described.

FIG. 22 shows information 2201 concerning a fixed period which is a planning material, and designates that the production plan is fixed when the planned completion date of the produced production plan is within the fixed period. Generally, a production plan is created in a fixed cycle. For example, if the production plan is fixed weekly, the production plan created with today as the base date is N
One week ahead is fixed. And one week later, 1
The week after is used as the reference date, and one week's worth N weeks ahead of the reference date is determined.

In FIG. 22, (Shopll, P-3038,
2001/12/17, 2001/12/23), the planned completion date of the production plan of the production item P-3038 in the process Shop 11 is designated by the effective start date 2001/12/17 and the effective end date 2001/12/23. It means that the production plan becomes a definite production plan when it is within the specified period.

Reference numeral 2301 in FIG. 23 indicates the process S of the base 1.
P-3038 2001/12/2 in hop11
The production plan is to produce 500 units by 2 and reference numeral 2302 indicates P- in the process Shop21 of the base 2.
The production plan is to produce 500 units of 3080-3 by 2001/12/20. Since the planned completion date of each production plan is within the effective start date and the effective end date, the finalized type is finalized.

Also, the production plan 230 of the item P-3038
1 is the production plan 2302 of the child item B-3080-3.
Therefore, the base 2 is set in the column indicating the allocation destination of 2301, and the base 1 is set in the column indicating the allocation source of 2302. FIG. 24 shows that allocation has occurred. Reference numerals 2401 and 4022 denote Shop1.
1, shows the production plan of Shop21, 2 of Shop11
Production plan 2401 of 001/12/22 is Shop2
The production plan 2402 of 2001/12/20 is allocated. If the supply LT between processes is "1", Sho
Item B-30 completed on p21 in 2001/12/20
80-3 will be delivered to Shop11 by 2001/12/21, and P-3038 will be produced on 2001/12/22.

As described above, when the finalized type and the allocation source are added to the production plan of each site and sent, the finalized type is the allocation source when the finalized type is fixed and the allocation source is set. It can be considered that the order form is issued from the base to the production base to which the production plan is sent. Similarly, when the fixed type and the allocation destination are set by sending the fixed type and the allocation destination added to the production plan of each base, the production is transmitted to the allocation destination base. It can be considered that the purchase order for the child items required by the plan has been issued. After that, the fact that the order has been placed or placed may be registered as a result in a system that manages the order or placed the order.

[0074]

According to the present invention, even if master data, which is a planning material, is distributed and managed in a plurality of bases, a production planning system that considers capacity restrictions and material restrictions of all bases involved in production activities. Therefore, it is possible to avoid problems such as delay of information due to orders moving between production bases, creation of non-executable plan due to lack of consideration of production restrictions of order destination, delay of delivery due to it, etc. This has the effect of shortening the planning cycle and enabling flexible response to demand fluctuations.

In addition, even in a base that does not have a production plan creation system based on an optimization method using mathematical programming or does not have the know-how to create a production plan based on the optimization method,
Since this is done on behalf of the requester, there is an effect that it is easy to create a production plan that takes into account the production restrictions of the own site and obtain an order that can be dealt with for the own site without disclosing the information to the request source.

[Brief description of drawings]

FIG. 1 is a diagram showing a configuration of a system including a production plan creating system according to an embodiment of the present invention.

FIG. 2 is a diagram showing an example of contents of planned materials.

FIG. 3 is a diagram showing an example of contents of planned materials.

FIG. 4 is a diagram showing an example of a parts table.

FIG. 5 is a diagram showing original data when creating a bottleneck model.

FIG. 6 is a diagram showing a production plan model created by a production plan creation technique according to an embodiment of the present invention.

FIG. 7 is a diagram showing a part of a production plan model created by the production plan creation technique according to the embodiment of the present invention.

FIG. 8 is a diagram showing how a bottleneck process is set by the production plan creation technique according to the embodiment of the present invention.

FIG. 9 is a diagram showing a bottleneck model created by a production plan creation technique according to an embodiment of the present invention.

FIG. 10 is a diagram showing data relating to a bottleneck model created by the production plan creation technique according to the embodiment of the present invention.

FIG. 11 is a diagram showing material restrictions in the production planning technique according to the embodiment of the present invention.

12 (a) and 12 (b) are diagrams respectively showing a shipping plan and a production plan created by a production plan creating technique according to an embodiment of the present invention.

FIG. 13 is a flowchart showing a production plan creating method according to an embodiment of the present invention.

FIG. 14 is a flowchart showing a method of transmitting / receiving production plan model data in the production plan creation technique according to the embodiment of the present invention.

FIG. 15 is a flowchart showing a production plan creation method in the production plan creation technique according to the embodiment of the present invention.

FIG. 16 is a diagram showing a production plan model of all bases in the production plan creation technique according to the embodiment of the present invention.

FIG. 17 is a diagram showing a state in which neck processes of different bases are connected in the production planning technique according to the embodiment of the present invention.

FIG. 18 is a diagram showing data for creating a production plan model for all bases in the production plan creation technique according to the embodiment of the present invention.

FIG. 19 is a diagram showing an outline of production plan model creation for all sites in the production plan creation technique according to the embodiment of the present invention.

FIG. 20 is a diagram showing an example of a production plan for each site.

FIG. 21 is a diagram showing item mapping in the production planning technique according to the embodiment of the present invention.

FIG. 22 is a diagram showing information on a fixed period which is a part of planned materials.

FIG. 23 is a diagram in which a fixed type, an allocation source, and an allocation destination are added to the production plan.

FIG. 24 is a diagram showing a production planning allocation relationship between different bases.

[Explanation of symbols]

101 ... Production plan creation system, 102 ... Production planning system, 103 ... Production plan creation means, 104 ... Production plan model management means, 105 ... Planning material input means, 106 ... Planning result output means, 107 ... Plan data communication, 108 ... Planning material, 109 ... Planning result, 201-306 ... Part of planning material, 501, 502 ... Data that is the source of production planning model creation, 601-1003 ... Data included in production planning model, 1201, 1202 ... Production planning As a result, 130
1-1305 ... Steps of production planning process, 141-
143 ... Steps of production planning model data transfer processing, 1
51-154 ... Steps of production plan creation processing at all sites,
1601-1605 ... Production planning model of each site, 160
6 ... Connection of production planning model between bases, 1613 ... Production planning model of all bases, 1801-1811 ... Source data for production planning model creation of all bases, 2201 ... Planning material regarding fixed period, 2301, 302 ... Order Production plan information 2401 used as information ... Allocation relationship of production plans between different bases.

Claims (7)

[Claims] 1. A step of reading out a planning material including information of at least one bottleneck step, a step of creating an overall production planning model based on the read out planning material, and a step of creating the entire production planning model. A step of extracting only information related to the bottleneck process, a step of creating a bottleneck model consisting of only the bottleneck process based on the extracted information related to the bottleneck process and the overall production planning model; A method for producing a production plan, which comprises the step of producing an optimized production plan for determining a production amount from a production demand amount by performing overall optimization on a bottleneck model. 2. A production plan creation method for creating production plans for all bases while linking production planning systems of a plurality of associated bases, wherein a production plan model created based on planning materials is used. At least one first site having a production plan creation means for creating a production plan by overall optimization reads out the first planning material including the information of at least one first bottleneck process, and reads out the first planning material. A first production planning model for the entire first base is created based on planning materials, and only the information related to the first bottleneck process is extracted from the overall first production planning model, and the extracted first bottleneck Creating a first bottleneck model consisting of only the first bottleneck process, based on a process and the overall first production plan model; and creating the production plan. At least one second site that does not have Dell reads out the second planned material including information on at least one second bottleneck process, and based on the read second planned material, the entire second site. A second production planning model of, and extracting only the information on the second bottleneck process from the overall second production planning model,
The extracted second bottleneck process and the second of the whole
A step of creating a second bottleneck model consisting of only the second bottleneck step based on a production planning model; and, according to a request from the first location, the first location from the second location
Sending the second bottleneck model to a base, and connecting the first bottleneck model and the second bottleneck model at the first base to obtain the first bottleneck model and the second bottle Creating an integrated bottleneck model that integrates the neck model, and performing an overall optimization on the integrated bottleneck model to create an optimized production plan for determining the production amount from the production demand; and Production planning method including. 3. The second base includes a plurality of bases, and a step of dividing the optimized production plan into a production plan required by each of the second bases and sending the divided production plans to the respective bases. The method for producing a production plan according to claim 2, further comprising: 4. The first base is a production planning proxy base that is not a production base, and the step of connecting the second bottleneck model to the first bottleneck model uses an item code common to all bases. 4. The production plan creation method according to claim 2, further comprising a step of identifying an item between each of the bases and associating the connected production bases by the item. 5. A production plan creating method for creating production plans for all sites while linking production planning systems of a plurality of associated sites, based on a production plan model created based on planning materials. At least one first site having a production plan creation means for creating a production plan by overall optimization sets information on at least one first bottleneck process and a fixed period between the effective production start date and the effective production end date. The first planning material including the first planning material is read, a first production planning model of the entire first base is created based on the read first planning material, and the first bottleneck process is performed from the first planning planning model of the whole. And a first bottom bottle consisting of only the first bottleneck process based on the extracted first bottleneck process and the entire first production planning model. A step of creating a neck model, and a second site including at least one site that does not have the production plan creation model reads out and reads out a second planning material including information of at least one second bottleneck process. A second production planning model for the second base as a whole is created based on the second planned material, and only the information relating to the second bottleneck process is extracted from the overall second production planning model and extracted. A step of creating a second bottleneck model consisting of only the second bottleneck step based on the second bottleneck step and the overall second production planning model; From the base to the first
Sending the second bottleneck model to a base, and connecting the first bottleneck model and the second bottleneck model at the first base to obtain the first bottleneck model and the second bottle A process of creating an integrated bottleneck model that is integrated with a neck model, and performing overall optimization on the integrated bottleneck model to create a production plan for determining a production amount from a production demand amount, When the completion date of the production plan is within the fixed period, the production plan is fixed, and
The production plan that has a relationship with the production plan is also confirmed,
A production plan including a step of issuing an order by issuing the production plan together with the allocation relationship and a step of dividing the production plan into a production plan required by each production site and sending the production plan to each production site. How to make. 6. At least one first base having a production plan creation means for creating a production plan by overall optimization based on a production plan model created based on planning materials, and the production plan creation model A production plan creation system for creating a production plan for all bases, including a second base including at least one base not associated with each other, and linking production plan systems of a plurality of associated bases, Based on the first planning material read out from the first storage means, which is provided at one base and stores the first planning material including information on at least one first bottleneck process, A first production planning model for the entire first base is created, and only the information relating to the first bottleneck process is extracted from the overall first production planning model, and the extracted first bottlenecks are extracted. A first processing means for creating a first bottleneck model consisting of only the first bottleneck process based on the process step and the first production plan model of the whole; and at least one first processing means provided at the second base. Second storage means for storing a second planned material including two bottleneck steps, and a second production planning model for the entire second base based on the second planned material read from the second storage means Then, only the information about the second bottleneck process is extracted from the overall second production planning model, and the second bottle is extracted based on the extracted second bottleneck process and the overall second production planning model. A second processing means for creating a second bottleneck model consisting only of a neck process; and a second processing means provided in each of the first and second bases. A first transmitting / receiving means for transmitting the second bottleneck model to a first base; and a first base, which is provided in the first base and connects the first bottleneck model and the second bottleneck model. Then, an integrated bottleneck model in which the first bottleneck model and the second bottleneck model are integrated is created, and overall optimization is performed on the integrated bottleneck model to determine the production amount from the production demand amount. And an optimized production plan creating means for creating an optimized production plan for dividing the optimized production plan provided in the first base into production plans required by each of the second bases. And a production plan creation system including a second transmitting / receiving means for sending to each base. 7. A production planning system for producing production plans for all the sites while linking production planning systems for a plurality of associated sites, based on a production plan model created based on planning materials. At least one having a production plan creating means for creating a production plan by optimization
No. 1 base reads out a first planned material including information on at least one first bottleneck process, and creates a first production planning model for the entire first base based on the read first planned material. Then, only the information about the first bottleneck process is extracted from the overall first production planning model, and the first bottle is extracted based on the extracted first bottleneck process and the overall first production planning model. A procedure for creating a first bottleneck model consisting of only a neck process, and a second site including at least one site that does not have the production plan creation model, a second site including information on at least one second bottleneck process. 2 planning material is read, a second production planning model for the entire second base is created based on the read second planning material, A second bottleneck model consisting of only the second bottleneck process is extracted based on the extracted second bottleneck process and the overall second production planning model by extracting only information related to the second bottleneck process. According to the procedure of creating and the request from the first base, the first base from the second base
A procedure of sending the second bottleneck model to a base, and connecting the first bottleneck model and the second bottleneck model at the first base to obtain the first bottleneck model and the second bottle Creating an integrated bottleneck model that integrates the neck model, and performing an overall optimization on the integrated bottleneck model, and a procedure for creating an optimized production plan for determining the production amount from the production demand and A program for causing a computer to execute a procedure of dividing the optimized production plan into production plans required by each of the second bases and sending the production plans from the first base to the respective bases.