JP5967992B2 - Production planning device, production planning method, and production planning program - Google Patents

Description

  The present invention relates to a production planning device, a production planning method, and a production planning program.

  In order to realize efficient production of products, it is important to make a suitable production plan. For example, in Patent Document 1, after drafting a part processing plan corresponding to an increase in the number of models of finished products, fluctuations in production amount, etc., for a neck process in which orders are concentrated, a processing plan for a process before and after the neck process is drafted. Techniques to do this are disclosed.

JP-A-11-852

  Various requirements such as the number of stocks and costs are involved in product production. For this reason, there is a need for evaluating a production plan from various viewpoints and thereby creating a suitable production plan. The present invention has been made in view of the above, and provides a production plan planning device, a production plan planning method, and a production plan planning program capable of formulating a suitable production plan evaluated from various viewpoints. With the goal.

  In one aspect, the production plan planning device calculates a product production plan based on shipment schedule information in which the production plan and the shipment schedule of the product are stored, and the inventory quantity of parts constituting the product. A production plan evaluation unit that evaluates based on an operation status of a production facility for producing the product and the parts calculated based on the production plan, and an evaluation value of the production facility, and the production plan evaluation A production plan search unit that searches for a suitable production plan based on the evaluation result of the unit.

  In another aspect, the production plan planning method is a production plan planning method executed by a production plan planning device, wherein the product production plan is based on shipment schedule information in which the production plan and the product shipment schedule are stored. The product and the inventory quantity of the parts that constitute the product, the operation status of the production facility for producing the product and the part calculated based on the production plan, and the evaluation value of the production facility And a step of searching for a suitable production plan based on a result of evaluating the production plan.

  In another aspect, the production plan planning program stores the product and the product calculated on the basis of shipment schedule information in which the production plan and the shipment schedule of the product are stored in the production plan planning apparatus. An evaluation based on an inventory quantity of components to be configured, an operation status of a production facility for producing the product and the component calculated based on the production plan, and an evaluation value of the production facility; And searching for a suitable production plan based on the result of evaluating the plan.

  The production plan planning device, the production plan planning method, and the production plan planning program according to the present invention have an effect that a suitable production plan evaluated from various viewpoints can be created.

FIG. 1 is a block diagram illustrating a configuration of a production plan planning apparatus according to the present embodiment. FIG. 2 is a diagram illustrating an example of configuration information. FIG. 3 is a diagram illustrating an example of production means information. FIG. 4 is a diagram illustrating an example of shipping schedule information. FIG. 5 is a diagram illustrating an example of inventory information. FIG. 6 is a diagram illustrating an example of the operation status evaluation parameter. FIG. 7 is a diagram illustrating an example of QCD evaluation parameters. FIG. 8 is a diagram illustrating an example of a change in inventory quantity with time. FIG. 9 is a diagram illustrating an example of evaluation values when order accuracy is taken into consideration. FIG. 10 is a diagram illustrating an example of evaluation values when order accuracy is not taken into consideration. FIG. 11 is a diagram illustrating an example of the evaluation of the operation status of the production facility. FIG. 12 is a diagram illustrating an example in which the criteria for evaluating the operation status of the production facility change. FIG. 13 is a flowchart showing the processing procedure of the production plan planning process. FIG. 14 is a flowchart showing the processing procedure of the neighborhood solution search process. FIG. 15 is a diagram illustrating an example of increasing the quantity of products or parts produced. FIG. 16 is a diagram illustrating an example of reducing the quantity of products or parts produced. FIG. 17 is a diagram illustrating an example of changing a time when a product or a part is produced. FIG. 18 is a diagram illustrating an example of changing a product or a part to be produced. FIG. 19 is a diagram illustrating an example of changing the production means. FIG. 20 is a diagram illustrating an example of production plan information in which an initial plan is stored. FIG. 21 is a diagram illustrating an example of production plan information in which a searched suitable production plan is stored.

  Embodiments of a production plan planning device, a production plan planning method, and a production plan planning program according to the present invention will be described below in detail with reference to the drawings. Note that the present invention is not limited to the embodiments. In addition, the constituent elements in this embodiment include those that can be easily assumed by those skilled in the art, those that are substantially the same, and those in a so-called equivalent range.

  First, the configuration of the production plan planning apparatus according to the present embodiment will be described. FIG. 1 is a block diagram illustrating a configuration of a production plan planning apparatus according to the present embodiment. A production plan planning apparatus 10 shown in FIG. 1 is connected to a production management system 20 and drafts a production plan for a product based on the planned shipment number of products managed by the production management system 20.

  In the present embodiment, the “production plan” refers to a plan indicating when and how much a product and its parts (materials) are produced using which production facility. In this embodiment, “product” means a product produced using a production facility, and does not necessarily mean a final product. That is, the “product” described in the present embodiment may include “parts” incorporated into other products.

  As shown in FIG. 1, the production plan planning device 10 includes a display unit 11, an input unit 12, a communication unit 13, a medium reading unit 14, a control unit 15, and a storage unit 16.

  The display unit 11 includes a display device such as a liquid crystal display (LED) or an organic EL display (OELD), and displays various information such as characters and figures based on a control signal transmitted from the control unit 15. The input unit 12 includes an input device such as a keyboard, and outputs a signal corresponding to an operation performed by the user to the input device to the control unit 15. The communication unit 13 controls transmission / reception of information with other devices based on a predetermined communication protocol. The medium reading unit 14 reads programs and data from a storage medium such as a CD-ROM, DVD-ROM, or memory card.

  The control unit 15 includes a CPU (Central Processing Unit) 151 that is a calculation unit and a memory 152 that is a storage unit, and implements various functions by executing programs using these hardware resources. Specifically, the control unit 15 reads out a program stored in the storage unit 16 and expands it in the memory 152, and causes the CPU 151 to execute an instruction included in the program expanded in the memory 152. The control unit 15 reads / writes data from / to the memory 152 and the storage unit 16 and controls the operation of the communication unit 13 and the like according to the execution result of the instruction by the CPU 151.

  The storage unit 16 includes a nonvolatile storage device such as a magnetic storage device or a semiconductor storage device, and stores various programs and data. The data stored in the storage unit 16 includes configuration information 161, production means information 162, shipping schedule information 163, inventory information 164, inventory evaluation parameters 165, operation status evaluation parameters 166, and QCD evaluation parameters 167. And production plan information 168. The programs stored in the storage unit 16 include a production planning program 169.

  Note that all or part of the programs and data that are stored in the storage unit 16 in FIG. 1 may be stored in a storage medium that can be read by the medium reading unit 14. Further, all or part of the program and data that the storage unit 16 stores in FIG. 1 may be acquired from another device through communication by the communication unit 13.

  The configuration information 161 holds information related to the product configuration. FIG. 2 is a diagram illustrating an example of the configuration information 161. As shown in FIG. 2, the configuration information 161 includes items such as a product number and a part number. The configuration information 161 is configured to hold a plurality of part number values for one product number value.

  The product number field stores a number for identifying a product to be produced. In the part number item, a number for identifying a part constituting the product is stored.

  In the first to third lines of the configuration information 161 shown in FIG. 2, the product identified by the product number “A01” is identified by the part identified by the part number “B01” and the part number “B02”. And a part identified by a part number “B03”. In the fourth to sixth lines of the configuration information 161 shown in FIG. 2, the product identified by the product number “A02” is identified by the part identified by the part number “B01” and the part number “B02”. And a part identified by a part number “B13”. In the seventh to ninth lines of the configuration information 161 shown in FIG. 2, the product identified by the product number “A03” is identified by the part identified by the part number “B21” and the part number “B22”. And a part identified by a part number “B23”.

In the present embodiment, it is assumed that the parts constituting the product are managed in only one hierarchy, but the configuration information 161 may be configured so that the parts constituting the product can be managed across a plurality of hierarchies. . In other words, the configuration information 161 may be configured to hold information related to the configuration of the component.

  The production means information 162 holds information related to production means for producing products or parts. In this embodiment, the “production means” means a combination of a production facility for producing a product or a part and a classification of whether the product or part is newly produced or produced by modification. The “production facility” is, for example, a factory, a production line, or a production apparatus. “Modification” refers to production of another product or part by adding, changing, or deleting the configuration of the product or part.

  FIG. 3 is a diagram illustrating an example of the production means information 162. As shown in FIG. 3, the production means information 162 includes items such as product / part number, production facility, and remodeling facility.

  In the product / part number item, a product number or a part number is stored. The production facility item stores a list of numbers for identifying production facilities used for newly producing corresponding products or parts. When there are a plurality of production facilities used for newly producing products or parts, numbers corresponding to the respective production facilities are stored in the item of the production facility. The remodeling facility item stores a list of combinations of numbers for identifying the production facility used to produce the corresponding product or part by remodeling and numbers for identifying the product or part to be remodeled. .

  In the first line of the production means information 162 shown in FIG. 3, the product identified by the product number “A01” is the production facility identified by the number “X01” or the production facility identified by the number “X02”. Shows that it can be newly produced. Further, in the first line of the production means information 162 shown in FIG. 3, the product identified by the product number “A01” is identified by the product number “A02” at the production facility identified by the number “X01”. The product can be produced by modifying the product identified by the product number “A02” at the production facility identified by the number “X02”.

  The third line of the production means information 162 shown in FIG. 3 indicates that the product identified by the product number “A03” can be newly produced only at the production facility identified by the number “X03”. Yes. Further, in the third line of the production means information 162 shown in FIG. 3, the item of the remodeling facility is blank. This is because the product identified by the product number “A03” is produced by remodeling other products. Indicates that you cannot do it.

  The shipping schedule information 163 holds information about when and how many products are scheduled to be shipped. FIG. 4 is a diagram illustrating an example of the shipping schedule information 163. As shown in FIG. 4, the shipping schedule information 163 includes a product number item, a shipping schedule quantity and an order accuracy item provided for each date.

  The product number field stores a number for identifying a product to be produced. In the item of the shipping scheduled quantity, the quantity scheduled to ship the product corresponding to the corresponding date is stored. The order accuracy item stores the accuracy with which a contract for shipping a product corresponding to a corresponding date can be received. In the order accuracy item, for example, “100%” is stored when the order is certain, and when the probability of losing is half, that is, the shipment of the product corresponding to the corresponding date becomes unnecessary. If the probability is half, “50%” is stored. The value of the order accuracy item may be set based on, for example, a sales representative's expectation, may be set based on past results, or may be set to a lower value as the date is earlier. May be set.

  The inventory information 164 holds information regarding the inventory of products and parts. FIG. 5 is a diagram illustrating an example of the inventory information 164. As shown in FIG. 5, the inventory information 164 includes items such as a product / part number, an appropriate inventory quantity, and an inventory quantity.

  In the product / part number item, a product number or a part number is stored. The appropriate stock quantity item stores the proper stock quantity of the corresponding product or part. The inventory quantity field stores the inventory quantity of the corresponding product or part at the start of the production plan.

  In the first line of the inventory information 164 shown in FIG. 5, “10” is appropriate for the product identified by the product number “A01”, but “15” at the start of the production plan. It shows that. In the second line of the inventory information 164 shown in FIG. 5, “10” is appropriate for the product identified by the product number “A02”, but “20” at the start of the production plan. It shows that. The third line of the inventory information 164 shown in FIG. 5 indicates that the inventory of the product identified by the product number “A03” is appropriate “10” at the start of the production plan. .

  The inventory evaluation parameter 165 holds information for evaluating a production plan from the viewpoint of inventory quantity. Evaluation of inventory quantity from the viewpoint of inventory quantity will be described later.

  The operation status evaluation parameter 166 holds information for evaluating the production plan from the viewpoint of the operation status of the production facility. FIG. 6 is a diagram illustrating an example of the operation status evaluation parameter 166. As shown in FIG. 6, the operation status evaluation parameter 166 includes items such as production facility, period, maximum production quantity, appropriate range upper limit value, appropriate range lower limit value, minimum production quantity, undertime evaluation coefficient, and overtime evaluation coefficient. . The operation status evaluation parameter 166 is configured to be able to hold a plurality of combinations of values of period to over-time evaluation coefficient for one production facility value.

  A number for identifying a production facility is stored in the production facility item, and a value indicating a period in which the value of the corresponding maximum production quantity to over-time evaluation coefficient item is valid is stored in the period item. The If there is no restriction on the period, the period item is blank.

  The maximum production quantity item stores the quantity of products or parts that can be produced when the corresponding production facility is fully operated. In the item of the appropriate range upper limit value, the upper limit of the appropriate range of the quantity of products or parts produced at the corresponding production facility is stored. The appropriate range lower limit value item stores the lower limit of the appropriate range of the quantity of products or parts produced at the corresponding production facility. The item of minimum production quantity stores the quantity of products or parts that should be produced at least in order to maintain the corresponding production facility.

  The under-evaluation coefficient item stores a coefficient used to calculate the evaluation value of the production plan when the production quantity of the product or part falls below the value of the appropriate range lower limit item. The over-evaluation coefficient item stores a coefficient used to calculate the evaluation value of the production plan when the production quantity of the product or part exceeds the value of the appropriate range upper limit value item. The evaluation of the inventory quantity from the viewpoint of the operation status of the production facility will be described later.

  The first line of the operation status evaluation parameter 166 shown in FIG. 6 shows that the production quantity of the production facility identified by the number “X01” is up to “December 2012” when the facility is operated to the maximum. “300” indicates that “250” to “150” are appropriate and should be “100” at the minimum. The second line of the operation status evaluation parameter 166 shown in FIG. 6 indicates that the production quantity of the production facility identified by the number “X01” is “January 2013” or later when the facility is operated to the maximum. “350” indicates that “300” to “150” are appropriate and should be “100” at least.

  The third line of the operation status evaluation parameter 166 shown in FIG. 6 indicates that the production quantity of the production facility identified by the number “X02” is “120” when the facility is operated to the maximum regardless of the period. Yes, “100” to “80” are proper and should be “50” at the minimum.

  In the present embodiment, it is assumed that the production quantity stored in the operation status evaluation parameter 166 is a value per month, but the production quantity stored in the operation status evaluation parameter 166 is not limited to this. The production quantity stored in the operation status evaluation parameter 166 may be, for example, a value per day, a value per week, a value per quarter value, or a value per year.

  The QCD evaluation parameter 167 holds information for evaluating the production plan from the viewpoint of the appropriateness of selection of the production facility. Specifically, the QCD evaluation parameter 167 holds information for evaluating the production plan from the viewpoint of the QCD of the selected production facility, that is, quality (Q), cost (C), and delivery date (D). . FIG. 7 is a diagram illustrating an example of the QCD evaluation parameter 167. As shown in FIG. 7, the QCD evaluation parameter 167 includes items of production facility and items of quality, cost, and delivery date provided separately for new production and remodeling.

  In the item of production facility, a number for identifying the production facility is stored. The quality item stores a value indicating the quality of a product or part produced by new production or modification at the corresponding production facility. In the quality item, for example, the yield rate (non-defective product rate) of products or parts is stored.

  In the item of cost, a value indicating the high cost of a product or part produced by new production or modification at the corresponding production facility is stored. In the item of cost, for example, a relative value with the production cost of the production facility having the highest production cost as 100 is stored. In the item of delivery date, a value indicating the certainty of delivery date of a product or part produced by new production or modification at the corresponding production facility is stored. In the item of delivery date, for example, the compliance rate of the delivery date of the product or part is stored.

  The first line of the QCD evaluation parameter 167 shown in FIG. 7 shows that the production facility identified by the number “X01” has a high quality of “99” and a high cost when newly producing a product or part. Is “100”, and the certainty of delivery is “100”. Further, the first line of the QCD evaluation parameter 167 shown in FIG. 7 shows that the production facility identified by the number “X01” has a high quality of “99” when the product or part is produced by remodeling, and the cost. The height of “50” is “100”, and the certainty of delivery date is “100”. As shown in this example, even if the production facilities are the same, the QCD may differ depending on whether a product or part is newly produced or produced by modification.

  The production plan information 168 stores the produced production plan. An example of the production plan information 168 will be described later.

  The production planning program 169 provides a function for creating a suitable production plan. The production plan planning program 169 includes an initial plan creation unit 169a, a production plan evaluation unit 169b, and a production plan search unit 169c.

  The initial plan creation unit 169a provides a function of creating an initial production plan (hereinafter, also referred to as “initial plan”) for producing products and parts based on the shipping schedule information 163 and the like. The initial plan may be any content plan. The initial plan is created based on, for example, the configuration information 161, the production means information 162, the shipping schedule information 163, the inventory information 164, and the like so that each product is shipped in the quantity scheduled for the scheduled date. . The initial plan may also be created so that proper inventory quantities of products and parts are maintained.

  The initial plan creation unit 169a can be realized by using an existing technique for creating a production plan or a technique that will be conceived in the future. The initial plan may be created by an external system such as the production management system 20 and transmitted to the production plan planning apparatus 10.

  The production plan evaluation unit 169b provides a function for evaluating a production plan. According to the function provided by the production plan evaluation unit 169b, the production plan is evaluated from the viewpoint of the inventory quantity, the operation status of the production facility, and the appropriateness of selection of the production facility. From the viewpoint of inventory quantity, a production plan that keeps the inventory quantity appropriate and does not cause a shortage is highly appreciated. From the viewpoint of the operation status of production facilities, production plans in which the production quantity of each production facility falls within an appropriate range are highly evaluated. From the viewpoint of the accuracy of selection of production facilities, production plans in which products and parts are produced using production facilities excellent in QCD are highly evaluated.

  The production plan search unit 169c provides a function of searching for a suitable production plan starting from the initial plan. Specifically, according to the function provided by the production plan search unit 169c, a suitable production plan is searched by the local search method as follows. First, the initial plan is the current production plan (hereinafter sometimes referred to as “current plan”). Then, the evaluation value of the current plan is compared with the evaluation value of the neighboring production plan in which a part of the current plan is changed. If the neighboring production plan is more highly evaluated, the neighboring production plan is regarded as the current plan. The Thus, the search is repeatedly executed until a predetermined end condition is satisfied.

  For example, a production plan in which the production quantity of a certain product or part on a certain day is increased or decreased by a certain number, a production plan in which the production date of a certain product or part is changed to another day, A production plan in which a product or part to be changed to another product or part or a production plan for a certain product on a certain day is changed to another production means is created.

  Next, the production plan evaluation will be described in more detail. The evaluation value Ev of the production plan is calculated using the following formula (1).

  Here, Ps is an evaluation value from the viewpoint of inventory quantity. Ws is a weight for adjusting the evaluation value from the viewpoint of inventory quantity. Po is an evaluation value from the viewpoint of the operating status of the production facility. Wo is a weight for adjusting the evaluation value from the viewpoint of the operating status of the production facility. Pqcd is an evaluation value from the viewpoint of the appropriateness of selection of the production facility. Wqcd is a weight for adjusting the evaluation value from the viewpoint of the appropriateness of selection of the production facility. The production planning apparatus 10 is configured such that various parameters such as Ws, Wo, and Wqcd can be set to arbitrary values by the user.

  In this embodiment, each evaluation value is calculated as a penalty. That is, the smaller the evaluation value calculated, the higher the evaluation of the production plan. The method of calculating the evaluation value is not limited to such a method, and the evaluation value may be calculated such that the larger the evaluation value calculated, the higher the evaluation of the production plan.

  The evaluation of the production plan from the viewpoint of inventory quantity will be described with reference to FIGS. FIG. 8 is a diagram illustrating an example of a change in inventory quantity with time. FIG. 9 is a diagram illustrating an example of evaluation values when order accuracy is taken into consideration. FIG. 10 is a diagram illustrating an example of evaluation values when order accuracy is not taken into consideration.

  In FIG. 8, a curve C <b> 1 shows a change over time in the stock quantity when the order accuracy of a certain product or part is taken into consideration. The stock quantity when taking into account the order accuracy is calculated by adding the value obtained by subtracting the shipment quantity taking into account the order accuracy from the production quantity in the production plan, with the stock quantity at the start of the production plan as the initial value. Is done. The inventory quantity at the start of the production plan is acquired from the inventory information 164. The shipment quantity in consideration of the order accuracy is calculated by multiplying the value of the item of the current day's collection quantity stored in the shipping schedule information 163 by the value of the item of the order accuracy of the day.

  In FIG. 8, a curve C <b> 2 indicates a change over time in the stock quantity when the order accuracy of a certain product or part is not taken into consideration. The stock quantity without taking into account the accuracy of the order is calculated by accumulating a value obtained by subtracting the shipment quantity without taking the order accuracy into consideration from the production quantity in the production plan, with the stock quantity at the start of the production plan as the initial value. Is done. The shipment quantity that does not consider the order accuracy is the value itself of the collection quantity item of the day stored in the shipment schedule information 163.

  The inventory quantity at each time point indicated by the curve C1 is assumed to be close to the actual inventory quantity at that time point because the order accuracy is considered. For this reason, the inventory quantity indicated by the curve C1 is preferably close to the appropriate inventory quantity of the corresponding product or part. Therefore, the production plan is evaluated more highly as the difference between the stock quantity and the appropriate stock quantity in consideration of the order accuracy is small.

  On the other hand, the stock quantity at each time point indicated by the curve C2 does not take into account the order accuracy, so that the stock quantity at each time point when the shipment is performed according to the planned shipment quantity, that is, the minimum stock quantity at each time point can be taken. Indicates the value. For this reason, there is no possibility that a shortage will occur if the inventory quantity indicated by the curve C2 is 0 or more, regardless of the appropriate inventory quantity. Therefore, the production plan is highly evaluated if the inventory quantity when the order accuracy is not considered is 0 or more.

  As described above, the evaluation of the production plan from the viewpoint of the inventory quantity is performed using the inventory quantity when the order accuracy is considered and the inventory quantity when the accuracy is not considered. That is, the evaluation value Ps from the viewpoint of inventory quantity is calculated using the following equation (2).

  Here, Psp is an evaluation value based on the inventory quantity when the order accuracy is considered, and Psm is an evaluation value based on the inventory quantity when the accuracy is not considered. The evaluation value Ps is calculated for each product or part, and for each day on which production is performed within a target period for which a production plan is created. In the above equation (1), the evaluation values Ps calculated for each product or part and for each day are added together.

  The evaluation value Psp is calculated using, for example, the following formula (3).

  Here, qsp is an inventory quantity in consideration of the order accuracy. qr is a proper stock quantity. The appropriate inventory quantity is acquired from the inventory information 164.

  When the inventory quantity in consideration of the order accuracy is larger than the appropriate inventory quantity, the evaluation value Psp is calculated using the function fs1 (). As shown in FIG. 9, the function fs1 () is set so that the penalty becomes larger as the surplus quantity of the inventory with reference to the appropriate inventory quantity increases.

  Even if there is a surplus in the stock, if the surplus is small, a large number of storage locations can be taken, but the problem is not great. Therefore, in the example shown in FIG. 9, the function fs1 () is a non-linear function in which the penalty remains relatively small when the surplus quantity is small. In addition, the more the shipment quantity (the more demand is), the smaller the size, or the lower the cost of the product or part, the fewer problems caused by the surplus in stock. Therefore, the function fs1 () may be set so that the penalty decreases as the shipment quantity increases (the demand increases), or the penalty decreases as the size decreases, and the cost decreases. It may be set so that the penalty becomes smaller as the value is lower.

  When the inventory quantity in consideration of the order accuracy is equal to the appropriate inventory quantity, the evaluation value Psp is 0, that is, a value indicating the highest evaluation.

  When the inventory quantity considering the order accuracy is smaller than the appropriate inventory quantity and 0 or more, the evaluation value Psp is calculated using the function fs2 (). As shown in FIG. 9, the function fs2 () is set so that the penalty becomes larger as qr−qsp, that is, the shortage quantity of inventory based on the appropriate inventory quantity increases.

  The fact that the inventory quantity is smaller than the appropriate inventory quantity means that there is a high possibility that a shortage will occur. The occurrence of missing items is a serious problem. Therefore, in the example illustrated in FIG. 9, the slope of the function fs2 () with respect to the fluctuation of the inventory quantity is larger than that of the function fs1 ().

  When the inventory quantity considering order accuracy is less than 0, that is, when a shortage occurs, the evaluation value Psp is calculated using the function fs3 (). As shown in FIG. 9, the function fs3 () is set so that the penalty increases as the quantity of missing parts increases as −qsp. The fact that there is actually a shortage is a very serious problem. Therefore, in the example shown in FIG. 9, the slope of the function fs3 () with respect to the fluctuation of the inventory quantity is larger than that of the function fs2 ().

  The evaluation value Psm is calculated using, for example, the following formula (4).

  Here, qsm is a stock quantity when the order accuracy is not considered.

  As described above, when the inventory quantity when the order accuracy is not considered is 0 or more, there is no shortage. For this reason, when the inventory quantity without considering the order accuracy is 0 or more, the evaluation value Psm is 0, that is, a value indicating the highest evaluation.

  When the inventory quantity when order accuracy is not taken into consideration is smaller than 0, that is, when there is a possibility that a shortage may occur, the evaluation value Psm is calculated using the function fs4 (). As shown in FIG. 10, the function fs4 () is set so that the penalty increases as the quantity of missing parts that can be generated increases.

  Information relating to Expression (3) and Expression (4) may be stored in the inventory evaluation parameter 165, or may be embedded in the production plan evaluation unit 169b.

  Next, the evaluation of the production plan from the viewpoint of the operation status of the production facility will be described with reference to FIGS. 11 and 12. FIG. 11 is a diagram illustrating an example of the evaluation of the operation status of the production facility. FIG. 12 is a diagram illustrating an example in which the criteria for evaluating the operation status of the production facility change.

  The bar graph in FIG. 11 shows the change over time of the monthly total value of the production quantities of products or parts in a certain production facility. For the monthly aggregate value of the production quantity of products or parts, for example, the production date and production quantity of the product or part produced using the production facility to be aggregated is extracted from the production plan, and the production quantity is added monthly. It is calculated by doing. A plurality of types of products or parts may be mixed in products or parts produced using the production facility to be counted.

  The evaluation value Po from the viewpoint of the operating status of the production facility is calculated using, for example, the following equation (5).

  Here, qp is a monthly total value of the production quantities of products or parts in the production facility. qul is an upper limit value of an appropriate range of the production quantity of the product or part in the production facility. qll is an appropriate range lower limit value of the production quantity of the product or part in the production facility. The appropriate range upper limit value and the appropriate range lower limit value are acquired from the operation status evaluation parameter 166. The evaluation value Po is calculated for each production facility and for each month within a period for which a production plan is created. In the above equation (1), the evaluation value Po calculated for each production facility and for each month is added up.

  When the production quantity falls between the upper limit value and the lower limit value of the appropriate range, the operation status of the production facility is appropriate. For this reason, in this case, the evaluation value Po is 0, that is, a value indicating the highest evaluation.

  When the production quantity exceeds the appropriate range upper limit value, the evaluation value Po is calculated using the function fo1 (). As shown in FIG. 11, the function fo1 () is set so that the penalty increases as the excess quantity of the production quantity based on qp-qul, that is, the appropriate range upper limit value is larger. In the example shown in FIG. 11, the production quantity exceeds the appropriate range upper limit value in September 2012 and November 2012, but the excess quantity is larger in September 2012. Therefore, the penalty P3 of the production facility in September 2012 is larger than the penalty P2 of the production facility in November 2012.

  When the production quantity falls below the appropriate range lower limit value, the evaluation value Po is calculated using the function fo2 (). As shown in FIG. 11, the function fo2 () is set so that the penalty becomes larger as qll-qp, that is, the shortage of the production quantity based on the appropriate range lower limit value increases. In the example shown in FIG. 11, the production quantity is below the appropriate range lower limit value in July 2012, and the penalty for the production facility in this month is the penalty P1.

  For example, the function fo1 () calculates Po by multiplying the excess quantity of the production quantity by the over-time evaluation coefficient of the facility stored in the operation status evaluation parameter 166. For example, the function fo2 () calculates Po by multiplying the shortage quantity of the production quantity by the under-evaluation coefficient of the facility stored in the operation status evaluation parameter 166.

  The production capacity of a production facility may fluctuate due to an increase in the number of equipment, an increase in the number of staff, etc. For example, in the example shown in FIG. 12, the production capacity of the production facility has been strengthened since January 2013, and the maximum production quantity and the appropriate range upper limit value are larger. Such a change in production capacity of the production facility can be dealt with by setting a period and setting a parameter for each period as in the example of the operation status evaluation parameter 166 shown in FIG. .

  The production plan planning device 10 may be configured to create a production plan so that the production quantity of each production facility does not exceed the maximum production quantity and does not fall below the minimum production quantity. In this case, for production quantities that exceed the maximum production quantity and production quantities that fall below the minimum production quantity, it is not necessary to calculate an evaluation value from the viewpoint of the operating status of the production facility.

  Next, the evaluation of the production plan from the viewpoint of the appropriateness of selection of the production facility will be described. The evaluation value Pqcd from the viewpoint of the appropriateness of selection of the production facility is calculated using, for example, the following formula (6).

  Here, Pq is an evaluation value related to the quality of products or parts produced at the production facility. Pq becomes smaller as the quality of products or parts produced in the production facility is higher. Pq is obtained, for example, by dividing the value of the quality item in the row corresponding to the production facility in the QCD evaluation parameter 167 from 100. The value of the quality item may vary depending on whether the product or part is newly produced or produced by modification. Wq is a weight for adjusting an evaluation value related to quality.

  Pc is an evaluation value related to the cost of the product or part produced at the production facility. Pc becomes smaller as the cost of products or parts produced in the production facility is lower. As the Pc, for example, the value of the cost item in the row corresponding to the production facility in the QCD evaluation parameter 167 is used as it is. The value of the cost item may vary depending on whether the product or part is newly produced or produced by modification. Wc is a weight for adjusting an evaluation value related to cost.

  Pd is an evaluation value related to the delivery date of the product or part produced at the production facility. Pd becomes so small that the delivery date of the product or part produced in the production facility is observed. Pd is obtained, for example, by dividing the value of the delivery date item of the line corresponding to the production facility in the QCD evaluation parameter 167 from 100. The value of the delivery date item may vary depending on whether the product or part is newly produced or produced by modification. Wd is a weight for adjusting the evaluation value related to the delivery date.

  The evaluation value Pcd is calculated for each product or part, and for each day on which production is performed within a target period for which a production plan is created. In the above equation (1), the evaluation values Pqcd calculated in this way for each product or part and for each day are added together.

  Next, with reference to FIG. 13 to FIG. 19, the processing procedure of the production plan planning process executed by the production plan planning apparatus 10 will be described. FIG. 13 is a flowchart showing the processing procedure of the production plan planning process. The processing procedure shown in FIG. 13 is realized by the control unit 15 executing the production plan planning program 169.

  As shown in FIG. 13, the control unit 15 first creates an initial plan (step S101). The control unit 15 sets the created initial plan as the current plan Pc and stores it in the production plan information 168 (step S102). The current plan Pc is the most preferable production plan searched at that time. Then, the control unit 15 calculates an evaluation value of the current plan Pc (Step S103).

  Subsequently, the control unit 15 creates a neighborhood solution Pn in which a part of the current plan Pc is changed by executing a neighborhood solution search process (step S104). Then, the control unit 15 calculates an evaluation value of the neighborhood solution Pn (step S105).

  When the evaluation value of the neighborhood solution Pn is smaller than the evaluation value of the current plan Pc, that is, when the neighborhood solution Pn has a higher evaluation than the current plan Pc (Yes in step S106), the control unit 15 sets the neighborhood solution Pn to the current value. The plan Pc is stored in the production plan information 168 (step S107). Then, the control unit 15 determines whether the end condition is satisfied (step S108).

  For example, the control unit 15 determines that the termination condition is satisfied in the following case. First, the control unit 15 evaluates all the production plans in the vicinity of the current plan Pc, but determines that the end condition is satisfied when there is no production plan with a higher evaluation than the current plan Pc. Further, the control unit 15 determines that the end condition is satisfied when the number of evaluations of the production plan is greater than the predetermined number. Further, the control unit 15 determines that the end condition is satisfied when the processing time of the production planning process becomes longer than a predetermined time. Further, the control unit 15 determines that the end condition is satisfied when the evaluation of the current plan Pc is sufficiently good, that is, when the evaluation value of the current plan Pc satisfies a predetermined condition. The predetermined condition is, for example, that the evaluation value is 0 or that the evaluation value is less than a sufficiently small threshold.

  When the end condition is satisfied (step S108, Yes), the control unit 15 sets the current plan Pc as the optimal solution (step S109), and ends the production plan planning process. When the end condition is not satisfied (No at Step S108), the control unit 15 re-executes Step S104 and the subsequent steps.

  If the evaluation value of the neighborhood solution Pn is greater than or equal to the evaluation value of the current plan Pc, that is, if the neighborhood solution Pn is not evaluated higher than the current plan Pc (step S106, No), the control unit 15 determines whether the end condition is satisfied. Is determined (step S108). When the end condition is satisfied (step S108, Yes), the control unit 15 sets the current plan Pc as the optimal solution (step S109), and ends the production plan planning process. When the end condition is not satisfied (No at Step S108), the control unit 15 re-executes Step S104 and the subsequent steps.

  FIG. 14 is a flowchart showing the processing procedure of the neighborhood solution search process. The processing procedure shown in FIG. 14 is realized by the control unit 15 executing the production planning program 169.

  As illustrated in FIG. 14, the control unit 15 first determines a target to be changed (step S201). The object to be determined is a combination of a date and a product or part. The target to be changed may be determined using a random number. Alternatively, a combination of a date with a maximum penalty and a product or a part may be determined as a target to be changed so that a suitable solution is searched early.

  Subsequently, the control unit 15 determines a target change method (step S202). In the present embodiment, as a method for changing the object, any one of a change in production quantity, a change in production time, a change in articles, and a change in production means can be selected. The method for changing the target may be determined using a random number. Alternatively, each time the target to be changed changes, the target changing method may be selected in a predetermined order.

  As shown in the example shown in FIG. 15, the production quantity is changed by increasing the quantity in which the target product or part is produced on the target day, or the target product or part on the target day as shown in FIG. This is a way to reduce the quantity of parts produced. The change in the number of production affects the evaluation value from the viewpoint of the inventory quantity and the evaluation value from the viewpoint of the operation status of the production facility. If a change in production quantity is selected, the number of changes in production quantity is also determined. The increase / decrease number of the production quantity may always be 1 or -1. The increase / decrease number of the production quantity may be determined using a random number within a predetermined range.

  In the current plan Pc, when there is no plan to produce the target product or part on the target day, the production means used for production is also determined. In this case, the change in the production number also affects the evaluation value from the viewpoint of the appropriateness of selection of the production facility.

  The change of the production time is a method of changing the time when the target product or part is produced, as in the example shown in FIG. The change of the production time affects the evaluation value from the viewpoint of the inventory quantity and the evaluation value from the viewpoint of the operation status of the production facility.

  The change of the article is a method of changing a product or a part produced on the target day as in the example shown in FIG. The article may be changed so that the production means used for producing the product or part does not change. In this case, the change of the article affects the evaluation value from the viewpoint of inventory quantity. Alternatively, the change of the article may include a change in which the production means used to produce the product or part changes. In this case, the change of the article affects the evaluation value from the viewpoint of the inventory quantity, the evaluation value from the viewpoint of the operation status of the production facility, and the evaluation value from the viewpoint of the appropriateness of the selection of the production facility.

  The change of the production means is a method of changing the production means for producing the product or part produced on the target day as in the example shown in FIG. The change of production means includes a change of switching between new production or production by remodeling while using the same production facility. The change of the production means affects the evaluation value from the viewpoint of the operation status of the production facility and the evaluation value from the viewpoint of the appropriateness of selection of the production facility.

  The method for changing the object is selected within a feasible range. For example, a change that causes a product or part that cannot be produced by modification to be produced by modification is not selected. If there is no inventory of the product or part to be modified, the change that causes the product or part to be produced by the modification is not selected. Changes that violate the maximum and minimum production volume constraints of the production facility are not selected. Changes that would duplicate use of production facilities already assigned to produce other products or parts are not selected.

  The production planning device 10 can produce the product or part after the change so that the product or part after the change can be produced in accordance with the change of the production quantity of the product or part, the change of the production time, or the change of the article. May be configured to change.

  When the change of the production quantity is determined as the change method (step S203, Yes), the control unit 15 determines the quantity to be changed (step S204). Subsequently, the control unit 15 changes the target production quantity in the current plan Pc by the determined quantity (step S205). And the control part 15 makes the production plan after a change the neighborhood solution Pn (step S214).

  When the change of the production time is determined as the change method (No at Step S203, Step S206, Yes), the control unit 15 determines the time after the change (Step S207). Subsequently, the control unit 15 changes the target production time in the current plan Pc to the determined time (step S208). And the control part 15 makes the production plan after a change the neighborhood solution Pn (step S214).

  When the change of the article is determined as the change method (step S206, No, step S209, Yes), the control unit 15 determines the changed product or part (step S210). Subsequently, the control unit 15 changes the current plan Pc so as to produce the determined product or part instead of the target product or part (step S211). And the control part 15 makes the production plan after a change the neighborhood solution Pn (step S214).

  If the change method is other than the above, that is, if the change of the production means is determined (No at Step S209), the control unit 15 determines the changed production means (Step S212). Subsequently, the control unit 15 changes the target production means in the current plan Pc to the determined production means (step S213). And the control part 15 makes the production plan after a change the neighborhood solution Pn (step S214).

  Next, an example of a production plan to be created will be described. FIG. 20 is a diagram illustrating an example of production plan information 168 in which an initial plan is stored. FIG. 21 is a diagram showing an example of production plan information 168 in which a searched suitable production plan is stored.

  Compared to the example shown in FIG. 20, in the example shown in FIG. 21, the production means on April 2 of the product identified by the product number “A01” is changed from new production to production by remodeling, and the production quantity Has decreased from 10 to 5. Further, as a result of this change, the stock quantity of the product identified by the product number “A02” is reduced by 5 because it is used for remodeling.

  In the initial plan, the product identified by the product number “A01” has an excessive inventory quantity, but due to this change, the inventory quantity is close to an appropriate quantity. Similarly, in the initial plan, the product identified by the product number “A02” has an excessive inventory quantity, but this change brings the inventory quantity close to an appropriate quantity. With these changes, the evaluation value from the viewpoint of inventory quantity has improved.

  In this embodiment, it is assumed that the cost of production by remodeling is lower than that of new production. For this reason, by changing the product production means identified by the product number “A01” from new production to production by remodeling, the evaluation value from the viewpoint of the appropriateness of selection of the production facility is improved.

  As described above, the production plan planning apparatus 10 according to the present embodiment can evaluate a production plan from various viewpoints and draft a suitable production plan.

  In addition, the aspect of this invention shown by said Example can be arbitrarily changed in the range which does not deviate from the summary of this invention. For example, the program shown in the above embodiment may be divided into a plurality of modules or may be integrated with other programs. In the above embodiment, the local search method is used to search for a suitable production plan. However, a suitable production plan may be searched using other solution search methods.

  In the above-described embodiment, the example in which the evaluation value is calculated so as to indicate that the smaller the value is, the better the production plan is. An evaluation value may be calculated so as to indicate that there is.

  Moreover, in the above embodiment, an example is shown in which the change in the number of inventory is managed every day, and the change in the number of production is managed every month. It may be arbitrarily changed according to the purpose.

  In the above-described embodiment, an example in which a product and a part are evaluated using the same parameter has been described. However, different parameters may be used for the product and the part.

DESCRIPTION OF SYMBOLS 10 Production planning apparatus 11 Display part 12 Input part 13 Communication part 14 Medium reading part 15 Control part 151 CPU
152 Memory 16 Storage 161 Configuration information
162 Production means information 163 Shipment schedule information 164 Inventory information 165 Inventory evaluation parameter 166 Operation status evaluation parameter 167 QCD evaluation parameter 168 Production plan information
169 Production plan planning program 169a Initial plan creation unit 169b Production plan evaluation unit 169c Production plan search unit 20 Production management system

Claims (12)

And production planning evaluation unit to evaluate the production plan of the product,
A production plan search unit for searching for a suitable production plan based on the evaluation result of the production plan evaluation unit ,
The production plan evaluation unit
An inventory quantity of the product and an inventory quantity of parts constituting the product, calculated based on the production plan and shipment schedule information in which a shipment schedule of the product is stored;
Calculated based on the production plan, the operation status of a production facility for producing the product and the parts,
An evaluation value of the production facility;
And evaluating the production plan for the product based on
A production plan planning device characterized in that the production plan is evaluated higher as the stock quantity calculated when order accuracy is considered is closer to the appropriate stock quantity set for each product and each part . The production plan evaluation unit, the inventory quantity is calculated without considering the order accuracy is smaller than 0, production planning apparatus according to claim 1, characterized in that to evaluate lower the production plan . 3. The production planning apparatus according to claim 1, wherein the evaluation value of the production facility can take different values depending on whether the product or the part is newly produced or produced by remodeling. . The evaluation value of production facilities, production planning apparatus according to any one of claims 1 to 3, characterized in that it comprises a value related to the quality of the product or the component produced by the facility. The evaluation value of production facilities, production planning apparatus according to any one of claims 1 to 4, characterized in that it comprises a value related to the cost of the product or the component produced by the facility. The evaluation value of production facilities, production planning apparatus according to any one of claims 1 to 5, characterized in that it comprises a value related to certainty of delivery of the product or the component produced by the facility . The production plan evaluation unit evaluates the production plan as low as the production amount for each production facility calculated based on the production plan deviates from an appropriate range set for each production facility. The production planning apparatus according to any one of claims 1 to 6 .   A production plan evaluation unit for evaluating a product production plan;
  A production plan search unit for searching for a suitable production plan based on the evaluation result of the production plan evaluation unit,
  The production plan evaluation unit
  An inventory quantity of the product and an inventory quantity of parts constituting the product, calculated based on the production plan and shipment schedule information in which a shipment schedule of the product is stored;
  Calculated based on the production plan, the operation status of a production facility for producing the product and the parts,
  An evaluation value of the production facility;
Evaluating the production plan of the product based on
  An evaluation value of the production facility may take a different value depending on whether the product or the part is newly produced or produced by remodeling. A production planning method executed by a production planning device,
And a step to evaluate the products of the production plan,
Comprises the steps of searching for a suitable production plan depending on the evaluation of the production plan,
In the step of evaluating the production plan,
An inventory quantity of the product and an inventory quantity of parts constituting the product, calculated based on the production plan and shipment schedule information in which a shipment schedule of the product is stored;
Calculated based on the production plan, the operation status of a production facility for producing the product and the parts,
An evaluation value of the production facility;
And evaluating the production plan for the product based on
A production planning method characterized in that the production plan is evaluated higher as the inventory quantity calculated in consideration of the accuracy of order receipt is closer to the appropriate inventory quantity set for each product and part .   A production planning method executed by a production planning device,
  Evaluating the production plan of the product;
  Searching for a suitable production plan based on the result of evaluating the production plan,
  In the step of evaluating the production plan,
  An inventory quantity of the product and an inventory quantity of parts constituting the product, calculated based on the production plan and shipment schedule information in which a shipment schedule of the product is stored;
  Calculated based on the production plan, the operation status of a production facility for producing the product and the parts,
  An evaluation value of the production facility;
Evaluating the production plan of the product based on
  The production planning method, wherein the evaluation value of the production facility may take different values depending on whether the product or part is newly produced or produced by remodeling. In production planning equipment,
And a step to evaluate the products of the production plan,
A step of searching for a suitable production plan depending on the evaluation of the production plan, to the execution,
In the step of evaluating the production plan,
An inventory quantity of the product and an inventory quantity of parts constituting the product, calculated based on the production plan and shipment schedule information in which a shipment schedule of the product is stored;
Calculated based on the production plan, the operation status of a production facility for producing the product and the parts,
An evaluation value of the production facility;
And evaluating the production plan for the product based on
A production plan planning program characterized in that the production plan is evaluated more highly as the stock quantity calculated when order accuracy is considered is closer to the appropriate stock quantity set for each product and each part .   In production planning equipment,
  Evaluating the production plan of the product;
  Searching for a suitable production plan based on the result of evaluating the production plan,
  In the step of evaluating the production plan,
  An inventory quantity of the product and an inventory quantity of parts constituting the product, calculated based on the production plan and shipment schedule information in which a shipment schedule of the product is stored;
  Calculated based on the production plan, the operation status of a production facility for producing the product and the parts,
  An evaluation value of the production facility;
Evaluating the production plan of the product based on
  An evaluation value of the production facility may take a different value depending on whether the product or the part is newly produced or produced by remodeling.

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