JP7708612B2 - Manufacturing instruction data generating device, manufacturing instruction data generating method, and manufacturing instruction data generating program - Google Patents

Description

The present invention relates to a manufacturing instruction data generation device, a manufacturing instruction data generation method, and a manufacturing instruction data generation program.

Patent document 1 states, "The manufacturing record management system of the present invention can manage, by means of a master definition, output definitions that define the contents of the manufacturing records to be output as manufacturing records and the output timing. Furthermore, the manufacturing record management system makes it possible to automatically output electronic manufacturing records simply by approving the recording of manufacturing operations, without the need for an operator (e.g., a manager) to output the manufacturing records. Furthermore, the manufacturing record management system is characterized by backing up the output manufacturing records to a backup server." (See paragraph 0009 of Patent document 1.)

JP 2012-141807 A

Here, a typical production management system for streamlining production planning operations has automated the generation of manufacturing instruction data, but there is a problem in that automation requires a lot of master setting work. Even with the technology described in Patent Document 1, the contents of the manufacturing record and the output timing must be defined in detail in the master.

For example, when registering a new product in the master data, the manufacturing location had to be registered along with the product in the master data file one by one, which made the master data setup cumbersome and prone to human error. In other words, it was previously difficult to achieve both ease of master data management and the convenience of automatically generating manufacturing instruction data.

The present invention has been made in consideration of the above problems, and aims to provide a manufacturing instruction data generation device, a manufacturing instruction data generation method, and a manufacturing instruction data generation program that can automatically generate manufacturing instruction data under easy master management.

In order to solve the above-mentioned problems and achieve the object, the manufacturing instruction data generating device according to the present invention is a manufacturing instruction data generating device having a control unit and a storage unit, the storage unit stores a specification master including product identification data for identifying a product and process pattern identification data for identifying a pattern of a process combination for manufacturing the product, the process pattern identification data, process identification data for identifying the process, and a process pattern master including a target value of the finished product for each process, and an allocation master including a general area which is a general area to which a manufacturing location where the product is manufactured belongs, the process identification data, the range of the target value, and the manufacturing location, and the control unit derives from the specification master a specification master including the product identification data and the general area. The system is characterized by comprising: a process pattern acquisition means for acquiring process pattern identification data linked to the product identification data in the source data; a process acquisition means for acquiring from the process pattern master process identification data and target values linked to the process pattern identification data acquired by the process pattern acquisition means; a manufacturing location acquisition means for acquiring from the allocation master a manufacturing location linked to the general area in the source data, linked to the process identification data acquired by the process acquisition means, and linked to the range to which the target value acquired by the process acquisition means belongs; and a manufacturing instruction data generation means for generating manufacturing instruction data including at least the product identification data in the source data, the process identification data and target values acquired by the process acquisition means, and the manufacturing location acquired by the manufacturing location acquisition means.

In the manufacturing instruction data generation device according to the present invention, the storage unit further stores a manufacturing location master including the manufacturing location and the lead time required for work at the manufacturing location, the control unit further includes a lead time acquisition means for acquiring, from the manufacturing location master, the lead time associated with the manufacturing location acquired by the manufacturing location acquisition means for each process in the manufacturing instruction data, and the manufacturing instruction data generation means stores the lead time acquired for each process by the lead time acquisition means in the manufacturing instruction data.

In the manufacturing instruction data generating device according to the present invention, the control unit further includes a planned work start date calculation means for calculating the planned work start date of the final process in the manufacturing instruction data by subtracting the lead time for the final process acquired by the lead time acquisition means from the production delivery date of the product, and for calculating the planned work start dates from the process immediately before the final process to the first process in the manufacturing instruction data by subtracting the lead times for each process acquired by the lead time acquisition means from the calculated planned work start date of the process immediately after, and the manufacturing instruction data generating means stores the planned work start dates of each process calculated by the planned work start date calculation means in the manufacturing instruction data.

In the manufacturing instruction data generating device according to the present invention, the storage unit further stores a manufacturing location master including the manufacturing location and a reference inventory location, and the control unit acquires from the manufacturing location master a reference inventory location linked to the manufacturing location acquired by the manufacturing location acquisition means for each process in the manufacturing instruction data, and further includes an inventory location acquisition means for acquiring an inventory issuing location, which is a location for discharging inventory when manufacturing starts, and an inventory recording location, which is a location for recording inventory when manufacturing is completed, for each process in the manufacturing instruction data based on the acquired reference inventory location, and the manufacturing instruction data generating means stores the reference inventory location, inventory issuing location, and inventory recording location acquired for each process by the inventory location acquisition means in the manufacturing instruction data.

The manufacturing instruction data generation device according to the present invention is also characterized in that the source data is order data or production plan data.

The manufacturing instruction data generation device according to the present invention is also characterized in that it is used by a material processing manufacturer, and the target value is the target size of the material after it has been processed in each process.

In addition, in the manufacturing instruction data generation method according to the present invention, a manufacturing instruction data generation method is executed by an information processing device having a control unit and a storage unit, the storage unit stores a specification master including product identification data for identifying a product and process pattern identification data for identifying a pattern of a combination of processes for manufacturing the product, the process pattern identification data, the process identification data for identifying the process, and a process pattern master including a target value of the finished product for each process, and an assignment master including a general area to which a manufacturing location where the product is manufactured belongs, the process identification data, the range of the target value, and the manufacturing location, and the control unit executes a process of extracting from the specification master a front part in the expansion source data including the product identification data and the general area. The method includes a process pattern acquisition step of acquiring process pattern identification data linked to the product identification data, a process acquisition step of acquiring from the process pattern master process identification data and target values linked to the process pattern identification data acquired in the process pattern acquisition step, a manufacturing location acquisition step of acquiring from the allocation master a manufacturing location linked to the general area in the source data, linked to the process identification data acquired in the process acquisition step, and linked to the range to which the target value acquired in the process acquisition step belongs, and a manufacturing instruction data generation step of generating manufacturing instruction data including at least the product identification data in the source data, the process identification data and target values acquired in the process acquisition step, and the manufacturing location acquired in the manufacturing location acquisition step.

In addition, the manufacturing instruction data generation program according to the present invention is a manufacturing instruction data generation program to be executed by an information processing device having a control unit and a storage unit, the storage unit stores a specification master including product identification data for identifying a product and process pattern identification data for identifying a pattern of a combination of processes for manufacturing the product, the process pattern identification data, the process identification data for identifying the process, and a process pattern master including a target value of the finished product for each process, and an assignment master including a general area which is a general area to which a manufacturing location where the product is manufactured belongs, the process identification data, the range of the target value, and the manufacturing location, and an expansion source including the product identification data and the general area is selected from the specification master for execution by the control unit. The method includes a process pattern acquisition step of acquiring process pattern identification data linked to the product identification data in the data, a process acquisition step of acquiring from the process pattern master process identification data and a target value linked to the process pattern identification data acquired in the process pattern acquisition step, a manufacturing location acquisition step of acquiring from the allocation master a manufacturing location linked to the general area in the source data, linked to the process identification data acquired in the process acquisition step, and linked to the range to which the target value acquired in the process acquisition step belongs, and a manufacturing instruction data generation step of generating manufacturing instruction data including at least the product identification data in the source data, the process identification data and the target value acquired in the process acquisition step, and the manufacturing location acquired in the manufacturing location acquisition step.

The present invention has the advantage of being able to automatically generate manufacturing instruction data with easy master management.

FIG. 1 is a block diagram showing an example of a configuration of a production instruction data generating device. FIG. 2 is a diagram showing an example of a processing flow in this embodiment. FIG. 3 is a diagram showing an example of the product master and the specification master. FIG. 4 is a diagram illustrating an example of the process master. FIG. 5 is a diagram showing an example of a process pattern master. FIG. 6 is a diagram showing an example of the factory-by-process manufacturing site allocation master. FIG. 7 is a diagram illustrating an example of the manufacturing location master. FIG. 8 is a diagram showing an example of the order data and the plan data at the start of processing. FIG. 9 is a diagram showing an example of the order data and the plan data after the factory allocation input. FIG. 10 is a diagram showing an example of the generated production instruction data. FIG. 11 is a diagram showing an example of the order data and the plan data after the process expansion process. FIG. 12 is a diagram showing an example of the warehouse LT master and the calendar master. FIG. 13 is a diagram showing an example of fictitious manufacturing instruction data 106k for use in explaining the previous process, the current process, and the next process. FIG. 14 is a diagram showing an example of fictitious production instruction data 106k used to explain the movement of work-in-process inventory.

Below, an embodiment of a manufacturing instruction data generation device, a manufacturing instruction data generation method, and a manufacturing instruction data generation program according to the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the present embodiment.

[1. Overview]
Material processing manufacturers purchase materials from suppliers and manufacture goods (products) through multiple processes according to product specifications. The manufacturing conditions must be determined based on customer requests, such as the type of material and size of the product, making production planning the process difficult. For this reason, this work is largely dependent on the know-how of experienced workers, but there is a growing need for technology to support this from a system perspective in order to reduce the workload in line with generational change, changes in the products handled, and work style reforms.

A typical production management system for streamlining production planning tasks has automated manufacturing instructions, but the challenge is that automation requires a lot of master data setting work. For example, traditionally, master data had to be registered for each product, even if the same manufacturing method was used. Also, although the manufacturing location can be determined based on the work content (for example, a packaging process is always performed on the packaging line), traditionally it was necessary to register the manufacturing location for each item, which was cumbersome and prone to human error.

In this embodiment, therefore, in order to improve the efficiency of production planning work and prevent human error at material processing manufacturers with many manufacturing processes and complex manufacturing conditions for each process, for example, the decision of manufacturing processes according to product specifications is automated, and master data required for automating manufacturing instructions is broken down by purpose, making master management easier and eliminating complexity. The present invention is particularly effective, for example, at steel material processing manufacturers and meat processing manufacturers with many manufacturing processes where equipment and locations can be determined for each process. In the meat processing industry, as an example of the manufacturing process, the manufacturing process is thawing meat → processing → salting → filling → heating → cooling → packaging. The specific configuration and operation are explained below.

2. Configuration
An example of the configuration of a manufacturing instruction data generating device 100 according to this embodiment will be described with reference to Fig. 1. Fig. 1 is a block diagram showing an example of the configuration of the manufacturing instruction data generating device 100.

The manufacturing instruction data generating device 100 is a commercially available desktop personal computer. Note that the manufacturing instruction data generating device 100 is not limited to a stationary information processing device such as a desktop personal computer, but may be a portable information processing device such as a commercially available notebook personal computer, a PDA (Personal Digital Assistant), a smartphone, or a tablet personal computer.

The manufacturing instruction data generating device 100 includes a control unit 102, a communication interface unit 104, a storage unit 106, and an input/output interface unit 108. Each unit included in the manufacturing instruction data generating device 100 is connected to each other so as to be able to communicate with each other via any communication path.

The communication interface unit 104 communicatively connects the manufacturing instruction data generating device 100 to the network 300 via a communication device such as a router and a wired or wireless communication line such as a dedicated line. The communication interface unit 104 has a function of communicating data with other devices via the communication line. Here, the network 300 has a function of connecting the manufacturing instruction data generating device 100 and the server 200 so that they can communicate with each other, and is, for example, the Internet or a LAN (Local Area Network). Note that data such as various masters described below may be stored in the server 200, for example.

An input device 112 and an output device 114 are connected to the input/output interface unit 108. The output device 114 may be a monitor (including a home television), a speaker, or a printer. The input device 112 may be a keyboard, a mouse, a microphone, or a monitor that works with a mouse to provide a pointing device function. In the following, the output device 114 may be referred to as the monitor 114, and the input device 112 may be referred to as the keyboard 112 or the mouse 112.

The storage unit 106 stores various databases, tables, files, and the like. The storage unit 106 records computer programs that work in cooperation with the OS (Operating System) to give instructions to the CPU (Central Processing Unit) to perform various processes. The storage unit 106 can be, for example, a memory device such as a RAM (Random Access Memory) or a ROM (Read Only Memory), a fixed disk device such as a hard disk, a flexible disk, an optical disk, or the like.

The memory unit 106 includes, for example, a product master 106a, a specification master 106b, a process master 106c, a process pattern master 106d, a factory-by-process manufacturing location allocation master 106e (hereinafter simply referred to as "allocation master 106e") as an allocation master, a manufacturing location master 106f, a warehouse LT master 106g, a calendar master 106h, order data 106i, planning data 106j as production plan data, and manufacturing instruction data 106k.

Before we explain the contents of each master and each piece of data, we will first explain the function of each master and the processing flow in this embodiment.

The following describes the outline of the functions of each master. In this embodiment, the instruction information (manufacturing instruction data 106k) required for manufacturing can be automatically generated (process expansion process) according to the manufacturing process pattern set in the product specifications of the order information (order data 106i) and production plan information (plan data 106j). The process pattern master 106d is a master that patterns standard manufacturing methods (processes, their order, and manufacturing conditions) by product classification (settings for each product are not required). The allocation master 106e is a master for setting manufacturing locations (separating manufacturing locations by process content) by process, manufacturing plant, and size (settings for each product are not required). The manufacturing location master 106f is a master for setting standard inventory locations, manufacturing lead times, and in-house or outsourced manufacturing by manufacturing location. The specification master 106b is a master for registering product specification information by product and registering standard manufacturing patterns.

The process flow in this embodiment will be described with reference to FIG. 2. First, as shown on the left side of FIG. 2, for made-to-order products, order data 106i is generated by inputting an order, while for forecast products, plan data 106j is generated by inputting a production plan. Next, as shown in the center of FIG. 2, a manufacturing facility is registered by inputting factory allocation for the generated order data 106i and plan data 106j. Then, based on the order data 106i and plan data 106j in which the manufacturing facility is registered, manufacturing instruction data 106k is automatically generated by referring to each master through process expansion processing. Finally, a manufacturing instruction sheet is output based on the generated manufacturing instruction data 106k.

The contents of each master and data are explained in detail below. In this embodiment, the target value includes all values. The manufacturing instruction data generation device 100 according to this embodiment is typically used by a material processing manufacturer, and in this case, the target value refers to the target size of the material after it has been processed in each process (for example, the target outer diameter).

The product master 106a is a master that registers information for each type of steel, for example. As shown in FIG. 3, the product master 106a includes, for example, product identification data (product code) for identifying the product, product number name, material classification, asset classification, the target size after the final process, etc.

The specification master 106b is a master for registering, for example, product specification information and process patterns. As shown in FIG. 3, the specification master 106b includes, for example, a specification management number, the product identification data (product code), the target size after the final process, the destination, process pattern identification data (process pattern code) for identifying the process combination pattern for manufacturing the product, and an inspection pattern code. In the example of the specification master 106b in FIG. 3, a process pattern specified by a process pattern code "1A200" is set for a product specified by a product code "1A250", and a process pattern specified by a process pattern code "1A250-01" is set for a product specified by a product code "1A2000300202".

The process master 106c is, for example, a master for registering process details. As shown in FIG. 4, the process master 106c includes, for example, process identification data (process code and process name) for identifying the process, a process classification, a start process input classification, a cost allocation classification, and the like.

The process pattern master 106d is, for example, a master for registering a manufacturing process pattern. In FIG. 5, Example 1 is the process pattern master 106d set for a product identified by product code "1A250", and Example 2 is the process pattern master 106d set for a product identified by product code "1A2000300202". As shown in FIG. 5, the process pattern master 106d includes, for example, the process pattern identification data (process pattern code), row number, process number, the process identification data (process code and process name), remarks, the target size, and the like. Information to be entered in the remarks includes, for example, manufacturing conditions.

The allocation master 106e is a master for setting the manufacturing location for each manufacturing facility (main factory), process, and size, for example. As shown in FIG. 6, the allocation master 106e includes, for example, the general area (manufacturing facility CD and manufacturing facility) to which the manufacturing location where the product is manufactured belongs, the process identification data (process code and process name), the target size range (applicable size), the manufacturing location (manufacturing location code and manufacturing location name), and the like. In FIG. 6, the applicable size "0" applies to a range of 0 or more and less than 2.810, and the applicable size "2.810" applies to a range of 2.810 or more.

The manufacturing location master 106f is a master for setting, for example, the reference inventory location (the reference location for inventory receipt and delivery), manufacturing lead time, and whether the location is an in-house location or an outsourced location for each manufacturing location. As shown in FIG. 7, the manufacturing location master 106f includes, for example, the manufacturing location (manufacturing location code and manufacturing location name), the reference inventory location (reference inventory location code and reference inventory location name), the lead time (manufacturing LT) required for work at the manufacturing location, the outsourcing process classification, and so on.

Here, the product master 106a and the specification master 106b are masters that require information registration every time the number of product types increases. In contrast, the process master 106c, the process pattern master 106d, the allocation master 106e, and the manufacturing location master 106f are masters that require information registration when the number of manufacturing locations increases or the manufacturing method is changed. Conventionally, every time the number of product types increases, it was necessary to set the master for the process for manufacturing the product and the manufacturing location where the product is manufactured, which was a cumbersome task. In contrast, in this embodiment, the process and manufacturing location do not need to be updated in the master every time during daily work, and they only need to be updated when a new process or new manufacturing location is added, so it can be said that the load of setting the master is light.

The warehouse LT master 106g is a master that sets the travel lead time, which is the lead time required to travel from the warehouse where production is completed to the shipping warehouse where shipping will take place. As shown in FIG. 12, the warehouse LT master 106g includes, for example, shipping warehouse identification data (shipping warehouse) for identifying the shipping warehouse, the general area (manufacturing facility), the travel lead time (lead time), and the like.

Calendar master 106h is a master for registering working days and holidays for each factory. As shown in FIG. 12, calendar master 106h includes, for example, the general area (calendar division), date, day of the week, and a division (holiday division) for indicating whether it is a working day or a holiday.

Order data 106i is data that manages information on made-to-order products (goods that are manufactured in response to an order). As shown in FIG. 8, etc., order data 106i includes, for example, an order number, an order line number, a serial number, an order delivery date, an order category, the product identification data (product code), the product number, the specification management number, the order quantity, the unit related to the order quantity, the general area (manufacturing facility), the process expansion processing date, and a shipping warehouse (shipping warehouse) that is a warehouse where the goods are shipped.

Plan data 106j is data that manages information on forecast production items (products that have not received orders but are expected to be produced). As shown in FIG. 8, etc., plan data 106j includes, for example, a plan number, a serial number, a production lead time, the product identification data (product code), the product number, the specification management number, the number of orders, the unit related to the number of orders, the general area (manufacturing facility), and the process expansion processing date.

Since the order data 106i and the plan data 106j are the data from which the manufacturing instruction data 106k is expanded, they can also be called the source data.

The manufacturing instruction data 106k is the data to be generated in this embodiment. As shown in FIG. 10, the manufacturing instruction data 106k includes the product identification data (product code), the serial number, the line number, the process number, the process identification data (process code and process name), the remarks, the target size, the manufacturing location (manufacturing location code and manufacturing location name), the base inventory location, the inventory issue location, the inventory recording location, the planned work start date (planned work date), the manufacturing delivery date, the manufacturing lead time (manufacturing LT), the number of instructions, and the like. The source of acquisition of each item is as shown at the top of the items in FIG. 10. Details of the base inventory location, the inventory issue location, and the inventory recording location are explained in [3-2-2] below.

The control unit 102 is a CPU or the like that performs overall control of the manufacturing instruction data generating device 100. The control unit 102 has an internal memory for storing control programs such as an OS, programs that define various processing procedures, required data, etc., and executes various information processing operations based on these stored programs.

The control unit 102 has, in terms of its functional concept, for example: (1) a process pattern acquisition unit 102a as a process pattern acquisition means for acquiring, from the specification master, process pattern identification data linked to the product identification data in the source data including the product identification data and the general area; (2) a process acquisition unit 102b as a process acquisition means for acquiring, from the process pattern master, process identification data and target values linked to the process pattern identification data acquired by the process pattern acquisition means; and (3) a process pattern acquisition unit 102c as a process pattern acquisition means for acquiring, from the allocation master, process identification data and target values linked to the general area in the source data, a manufacturing location acquisition unit 102c as manufacturing location acquisition means for acquiring a manufacturing location linked to the process identification data acquired by the process acquisition means and linked to the range to which the target value acquired by the process acquisition means belongs; (4) a lead time acquisition unit 102d as lead time acquisition means for acquiring, for each process in the manufacturing instruction data, a lead time linked to the manufacturing location acquired by the manufacturing location acquisition means from the manufacturing location master; and (5) a scheduled start date of work for the final process in the manufacturing instruction data, based on the manufacturing delivery date of the product, based on the final process acquired by the lead time acquisition means. a scheduled work start date calculation unit 102e as a scheduled work start date calculation means for calculating a scheduled work start date from the last process to the first process in the manufacturing instruction data by subtracting the lead time for each process acquired by the lead time acquisition means from the calculated scheduled work start date of the process one step after the final process; (6) acquiring, from the manufacturing location master, a standard inventory location linked to the manufacturing location acquired by the manufacturing location acquisition means for each process in the manufacturing instruction data, and further acquiring the acquired standard inventory location. The system includes an inventory location acquisition unit 102f as an inventory location acquisition means that acquires, for each process in the manufacturing instruction data, an inventory issuing location from which inventory is removed when manufacturing starts and an inventory recording location from which inventory is recorded when manufacturing is completed based on the warehouse location, and (7) a manufacturing instruction data generation unit 102g as a manufacturing instruction data generation means that generates manufacturing instruction data including at least the product identification data in the source data, the process identification data and target value acquired by the process acquisition means, and the manufacturing location acquired by the manufacturing location acquisition means.

The process pattern acquisition unit 102a acquires the process pattern code linked to the product code in the order data 106i or the plan data 106j (see FIG. 8) from the specification master 106b (see FIG. 3) that includes the product code and the process pattern code.

The process acquisition unit 102b acquires the process code and the target size associated with the process pattern code acquired by the process pattern acquisition unit 102a from the process pattern master 106d (see FIG. 5), which includes the process pattern code, the process code, and the target size.

The manufacturing location acquisition unit 102c acquires, from the allocation master 106e (see FIG. 6) that includes the manufacturing facility, the process code, the applicable size, and the manufacturing location, a manufacturing location that is linked to the manufacturing facility in the order data 106i or the plan data 106j (see FIG. 8), is linked to the process code acquired by the process acquisition unit 102b, and is linked to the applicable size to which the target size acquired by the process acquisition unit 102b belongs.

The lead time acquisition unit 102d acquires the production LT linked to the production location acquired by the production location acquisition unit 102c from the production location master 106f (see FIG. 7), which includes the production location and the production LT.

The planned work start date calculation unit 102e calculates the planned work start date of the final process in the manufacturing instruction data 106k by subtracting the lead time for the final process acquired by the lead time acquisition unit 102d from the production delivery date of the product. The planned work start date calculation unit 102e also calculates the planned work start dates from the process immediately before the final process to the first process in the manufacturing instruction data 106k by subtracting the lead times for each process acquired by the lead time acquisition unit 102d from the calculated planned work start date for the process immediately following. The method of calculating the planned work start date will be explained in detail in [3-2-1] below.

The inventory location acquisition unit 102f acquires, for each process in the manufacturing instruction data 106k, a reference inventory location linked to the manufacturing location acquired by the manufacturing location acquisition unit 102c from the manufacturing location master 106f (see FIG. 7) that includes the manufacturing location and the reference inventory location. Furthermore, the inventory location acquisition unit 102f acquires, for each process in the manufacturing instruction data 106k, an inventory issuing location, which is a location for discharging inventory when manufacturing starts, and an inventory recording location, which is a location for recording inventory when manufacturing is completed, based on the acquired reference inventory location. The method of acquiring the inventory issuing location and the inventory recording location will be explained in detail in [3-2-2] below.

The manufacturing instruction data generation unit 102g generates manufacturing instruction data 106k (see FIG. 10) that includes at least the product code in the order data 106i or the plan data 106j (see FIG. 8), the process code and target size acquired by the process acquisition unit 102b, and the manufacturing location acquired by the manufacturing location acquisition unit 102c.

The manufacturing instruction data generating unit 102g may further store the following information in the manufacturing instruction data 106k.
The manufacturing lead time acquired for each process by the lead time acquisition unit 102d
The planned work start date of each process calculated by the planned work start date calculation unit 102e. The reference stock location, stock issue location, and stock recording location acquired for each process by the stock location acquisition unit 102f.

3. Specific examples of processing
In this section, a specific example of the processing according to this embodiment will be described. In this section, it is assumed that the source data is previously registered with order data 106i consisting of three records and plan data 106j consisting of one record, as shown in Fig. 8. Also, in this section, it is assumed that the various master data are previously registered with the contents shown in Figs. 3 to 7.

[3-1. Factory allocation input]
First, the main manufacturing factory determined in advance by the production planner is registered as the manufacturing establishment in the source data through factory allocation input.

Factory allocation entry is performed on records in the order data 106i where "order type = manufacturing and manufacturing facility = blank" and records in the plan data 106j where "manufacturing facility = blank" are targeted. With reference to FIG. 8, the record with order number JU0002 in the order data 106i and the record with plan number KE0001 in the plan data 106j are targeted. In this example, as shown in FIG. 9, "Okayama" is registered as the manufacturing facility for both records.

[3-2. Process expansion processing]
Next, the manufacturing instruction data 106k is generated and the source data is updated by the process expansion process.

The process expansion process is performed on records in the order data 106i where "order type = manufacturing, manufacturing facility ≠ blank, and process expansion processing date = blank" and records in the plan data 106j where "manufacturing facility ≠ blank, and process expansion processing date = blank". In this example, the two records shown in Figure 9 are targeted. The process expansion process performed on these two records is similar, so below, the generation of manufacturing instruction data 106k based on the order data 106i in Figure 9 will be described in detail.

First, the process pattern acquisition unit 102a acquires "1A200" from the specification master 106b in FIG. 3 as the process pattern code associated with the product code "1A250" in the record of order number JU0002 in the order data 106i in FIG. 9.

Next, the process acquisition unit 102b acquires the row number, process number, process code, process name, remarks, and target size associated with the process pattern code "1A200" acquired by the process pattern acquisition unit 102a from the process pattern master 106d in Fig. 5. To explain the acquisition of the process name and target size, the process acquisition unit 102b acquires "Process = Allocation/Shipping, Target Size = 4.000", "Process = Wire Drawing, Target Size = 3.080", "Process = Straightening + Chamfering, Target Size = 3.080", "Process = Finish Polishing, Target Size = 3.000", "Process = Standard Inspection, Target Size = 3.000", and "Process = Packaging, Target Size = 3.000" from the process pattern master 106d of Example 1 shown in Fig. 5.

Next, the manufacturing location acquisition unit 102c acquires a manufacturing location code and a manufacturing location name that are linked to the manufacturing establishment "Okayama" in the order data 106i in FIG. 9, that are linked to the process acquired by the process acquisition unit 102b, and that are linked to the applicable size to which the target size acquired by the process acquisition unit 102b belongs. That is, the manufacturing location acquisition unit 102c
● For the process "Allocation/Shipping", obtain the manufacturing location "1H: Okayama Allocation/Shipping"
● For the process "wire drawing", we obtained the manufacturing location "1D3: Okayama Sanka Wire Drawing",
● For the process "Straight line + chamfering", obtain the manufacturing location "1S2: Okayama Sanka Straight Line";
For the process "finish polishing", obtain the manufacturing location "1G4: Okayama Second Polishing" which is linked to the applicable size 2.810 (= 2.810 or more) to which the target size 3.000 belongs,
● For the process "Standard Inspection", obtain the manufacturing location "1I3: Okayama Daini Appearance"
●For the process "packaging", obtain the manufacturing location "1P3: Okayama Third Packaging".

Then, the production instruction data generation unit 102g generates the seven records above the thick line in the production instruction data 106k in Figure 10 (the records for product code "1A250") based on the order data 106i in Figure 9. In these seven records, the product code "1A250", the serial number "SE00002", and the order quantity "600" correspond to the product code "1A250", the serial number "SE00002", and the order quantity "600" in the record for order number JU0002 in the order data 106i in Figure 9, the row number, process number, process code, process name, remarks, and target size correspond to the information acquired by the process acquisition unit 102b, and the manufacturing location code and manufacturing location name correspond to the information acquired by the manufacturing location acquisition unit 102c. In addition, although detailed explanation is omitted, the manufacturing instruction data generation unit 102g generates the eight records below the thick line in the manufacturing instruction data 106k in FIG. 10 (records with product code "1A2000300202") based on the planning data 106j in FIG. 9.

As shown in FIG. 10, the manufacturing instruction data generation unit 102g also stores the planned work date, production delivery date, and production LT, as well as the reference stock location, stock issue location, and stock recording location in the manufacturing instruction data 106k. The acquisition of the planned work date, production delivery date, and production LT (function 1) is described in [3-2-1] below, and the acquisition of the reference stock location, stock issue location, and stock recording location (function 2) is described in [3-2-2] below.

When the process expansion process is completed (= when the generation of manufacturing instruction data 106k is completed), the process expansion process date (2021/7/15) in the order data 106i and the plan data 106j is registered as shown in FIG. 11.

[3-2-1. Obtaining production lead time, production LT and scheduled work date (Function 1)]
(1) Obtaining the manufacturing lead time When generating the manufacturing instruction data 106k based on the order data 106i, the manufacturing lead time is calculated by subtracting the lead time days in the warehouse LT master 106g from the order lead time in the order data 106i (in FIG. 8, 2021/4/27 in the record of order number JU0002). Here, in the order data 106i in FIG. 11, since the manufacturing facility is Okayama and the shipping warehouse is the Okayama warehouse, "1" is obtained as the lead time days from the warehouse LT master 106g in FIG. 12. Therefore, the manufacturing lead time of the product with the product code "1A250" is "2021/4/26", which is the date obtained by subtracting 1 lead time day from the order lead time 2021/4/27.

In contrast, when the manufacturing instruction data 106k is generated based on the planning data 106j, the manufacturing delivery date becomes the manufacturing delivery date in the planning data 106j (in FIG. 11, 2021/4/27).

(2) Acquisition of manufacturing LT The lead time acquisition unit 102d acquires the manufacturing LT (manufacturing lead time) linked to the manufacturing location acquired by the manufacturing location acquisition unit 102c from the manufacturing location master 106f in Fig. 7. The acquisition of the manufacturing LT linked to the manufacturing location acquired by the manufacturing location acquisition unit 102c in [3-2] will be described below. The lead time acquisition unit 102d acquires the manufacturing LT linked to the manufacturing location acquired by the manufacturing location acquisition unit 102c from the manufacturing location master 106f in Fig. 7.
● For the production location "1H: Okayama Allocation/Shipping" corresponding to the process "Allocation/Shipping", obtain production LT "1".
● For the manufacturing location "1D3: Okayama Sanka Wire Drawing" corresponding to the process "Wire Drawing", obtain manufacturing LT "2",
● For the manufacturing location "1S2: Okayama Sanka Straight Line" corresponding to the process "Straight Line + Chamfering", obtain Manufacturing LT "2",
● For the manufacturing location "1G4: Okayama Second Polishing" corresponding to the process "finish polishing", manufacturing LT "3" was obtained.
● For the manufacturing location "1I3: Okayama Second Appearance" corresponding to the process "Standard Inspection", obtain manufacturing LT "1",
● For the manufacturing location "1P3: Okayama Third Packaging" corresponding to the process "packaging", obtain the manufacturing LT "1".

(3) Acquisition of Scheduled Work Date The scheduled work start date calculation unit 102e calculates the scheduled work date (scheduled work start date) for each process. The following describes the production LT for the product with product code "1A250" acquired by the lead time acquisition unit 102d in (2).

The planned work start date calculation unit 102e calculates the planned work start date for the final process by subtracting the lead time for the final process acquired by the lead time acquisition unit 102d from the production lead time of the product with product code "1A250". The production lead time of the product with product code "1A250" is "4/26/2021" as calculated in (1). On the other hand, the production LT for the final process, "packaging", is "1" as acquired in (2). Therefore, the planned work start date calculation unit 102e calculates the planned work start date for the final process for the product with product code "1A250" as 4/25/2021 by subtracting the production LT "1" from 4/26/2021.

The scheduled work start date calculation unit 102e calculates the scheduled work start dates from the process immediately before the final process to the first process by subtracting the lead time for each process acquired by the lead time acquisition unit 102d from the calculated scheduled work start date for the process immediately after.
The planned start date for the "standard inspection" process, which is one process before the final "packaging" process, is calculated as 2021/4/24 by subtracting the production LT "1" obtained for the "standard inspection" process in (2) from the planned start date for "packaging" calculated in (2) of 2021/4/25.
The planned start date for the process "finish polishing", which is one step before the process "standard inspection", is calculated as 2021/4/21 by subtracting the production LT "3" obtained for the process "finish polishing" in (2) from the calculated planned start date 2021/4/24,
The planned start date for the process "Straight line + chamfering", which is one step before the process "Finish polishing", is calculated as 2021/4/19 by subtracting the production LT "2" obtained for the process "Straight line + chamfering" in (2) from the calculated planned start date 2021/4/21.
The planned start date of the process "wire drawing", which is one step before the process "straightening + chamfering", is calculated as 2021/4/17 by subtracting the production LT "2" obtained for the process "wire drawing" in (2) from the calculated planned start date 2021/4/19,
The planned start date for the first process, “Allocation / Shipping”, which is the process immediately preceding the “Wiredrawing” process, is calculated as 2021/4/16 by subtracting the production LT “1” obtained for the “Allocation / Shipping” process in (2) from the calculated planned start date, 2021/4/17.

The planned work start date calculation unit 102e may refer to the calendar master 106h in FIG. 12 to calculate the planned work start date by including only the factory's operating days in the calculation (i.e., ignoring non-working days in the calculation). In this example, for the sake of simplicity, an example of calculating the planned work start date without referring to the calendar master 106h has been described.

(4) Reflection in manufacturing instruction data As shown in the seven records above the thick line in manufacturing instruction data 106k in FIG. 10 (the records for product code "1A250"), the manufacturing instruction data generation unit 102g stores the manufacturing delivery date (2021/4/26) for the product with product code "1A250" obtained in (1), the manufacturing LT for each process obtained in (2), and the planned work start date for each process obtained in (3) in the manufacturing instruction data 106k.

[3-2-2. Acquisition of base inventory location, inventory issuing location and inventory recording location (Function 2)]
(1) Definitions and Concepts of Terms First, the definitions of the terms base inventory location, inventory issue location, and inventory recording location are explained. The base inventory location is the location that serves as the base for inventory entry and exit. The inventory issue location and inventory recording location are information that makes it possible to know which warehouse has work-in-progress inventory. The inventory issue location is the location from which inventory is withdrawn when production begins, and can also be called the inventory withdrawal location. The inventory recording location is the location from which inventory is recorded when production is completed.

Next, we will explain the definitions of the terms previous process, current process, and next process. The previous process is the process immediately before the process that determines the inventory issue location and inventory recording location. The current process is the process that determines the inventory issue location and inventory recording location. The next process is the process immediately after the process that determines the inventory issue location and inventory recording location.

The concepts of previous process, current process, and next process are explained using FIG. 13. Note that FIG. 13 shows fictitious manufacturing instruction data 106k used only in the explanation of this section (1), and has no correlation with the manufacturing instruction data 106k in FIG. 10. In the example of FIG. 13, when determining the inventory issuing location, reference inventory location, and inventory recording location for process No. 2, process No. 2 is the current process, process No. 1 is the previous process, and process No. 3 is the next process. For this reason, there is no previous process for process No. 1, which is the first process No, and there is no next process for process No. 3, which is the last process No.

(2) How to obtain the reference stock location, the stock issuing location, and the stock recording location The stock location obtaining unit 102f first obtains the reference stock location. Specifically, the stock location obtaining unit 102f obtains the reference stock location linked to the manufacturing location obtained by the manufacturing location obtaining unit 102c from the manufacturing location master 106f.

The inventory location acquisition unit 102f then acquires the inventory recording location. Specifically, if the condition that the current process is an outsourced process and is not the final process is met, the inventory location acquisition unit 102f acquires the reference inventory location of the next process in the manufacturing instruction data 106k as the inventory recording location. If this condition is not met, the inventory location acquisition unit 102f acquires the reference inventory location of the current process in the manufacturing instruction data 106k as the inventory recording location.

Finally, the inventory location acquisition unit 102f acquires the inventory issuing location. Specifically, if the condition that the process number is 1 is met, the inventory location acquisition unit 102f acquires the reference inventory location of the current process in the manufacturing instruction data 106k as the inventory issuing location. If this condition is not met, the inventory location acquisition unit 102f acquires the inventory recording location of the previous process in the manufacturing instruction data 106k as the inventory issuing location.

(3) Specific Examples of Reflection in Manufacturing Instruction Data and Movement of Work-in-Process Inventory The manufacturing instruction data generating unit 102g stores the reference inventory location, inventory issuing location, and inventory posting location obtained based on the rule in (2) in the manufacturing instruction data 106k.

Figure 14 shows how work-in-process inventory moves in manufacturing instruction data 106k that has been updated by storing the reference inventory location, inventory issue location, and inventory recording location. Please note that Figure 14 is fictitious manufacturing instruction data 106k that is used only in the explanation of this section (3), and has no correlation with the manufacturing instruction data 106k in Figures 10 and 13. When the reference inventory location, inventory issue location, and inventory recording location for each process are as shown in Figure 14, the status of work-in-process inventory movement for each process will be as shown in the "Work-in-process inventory status explanation" in the right column of Figure 14.

[4. Summary of the present embodiment]
In this way, the manufacturing instruction data generating device 100 according to this embodiment can automatically generate the manufacturing instruction data 106k under easy master management. Specifically, the product master 106a and the specification master 106b require information registration every time the number of product types increases, but the process master 106c, the process pattern master 106d, the allocation master 106e, and the manufacturing site master 106f require information registration only when the number of manufacturing sites increases or the manufacturing method is changed, so that the load of master setting is light.

[5. Contribution to the United Nations-led Sustainable Development Goals (SDGs)]
This embodiment can contribute to improving business efficiency and promoting appropriate management decisions by companies, thereby making it possible to contribute to goals 8 and 9 of the SDGs.

In addition, this embodiment can contribute to reducing waste and promoting paperless and electronic systems, which can contribute to the achievement of SDGs goals 12, 13, and 15.

In addition, this embodiment can contribute to strengthening control and governance, making it possible to contribute to Goal 16 of the SDGs.

6. Other embodiments
The present invention may be embodied in various different embodiments other than those described above within the scope of the technical concept set forth in the claims.

For example, among the processes described in the embodiments, all or part of the processes described as being performed automatically can be performed manually, or all or part of the processes described as being performed manually can be performed automatically using a known method.

In addition, the processing procedures, control procedures, specific names, registered data for each process, information including parameters such as search conditions, screen examples, and database configurations shown in this specification and drawings may be changed as desired unless otherwise specified.

Furthermore, with regard to the manufacturing instruction data generating device 100, each component shown in the figure is a functional concept, and does not necessarily have to be physically configured as shown in the figure.

For example, the processing functions of the manufacturing instruction data generating device 100, particularly the processing functions performed by the control unit, may be realized in whole or in part by a CPU and a program interpreted and executed by the CPU, or may be realized as hardware using wired logic. The program is recorded on a non-transient computer-readable recording medium that contains programmed instructions for causing the information processing device to execute the processes described in this embodiment, and is mechanically read by the manufacturing instruction data generating device 100 as necessary. That is, a computer program for giving instructions to the CPU in cooperation with the OS and performing various processes is recorded in a storage unit such as a ROM or HDD (Hard Disk Drive). This computer program is executed by being loaded into RAM, and cooperates with the CPU to form the control unit.

This computer program may also be stored in an application program server connected to the manufacturing instruction data generating device 100 via any network, and all or part of it may be downloaded as needed.

In addition, the program for executing the processing described in this embodiment may be stored on a non-transitory computer-readable recording medium, and may also be configured as a program product. Here, the term "recording medium" refers to a memory card, a USB (Universal Serial Bus) memory, a SD (Secure Digital) card, a flexible disk, a magneto-optical disk, a ROM, an EPROM (Erasable Programmable Read Only Memory), an EEPROM (registered trademark) (Electrically Erasable and Programmable Read Only Memory), a CD-ROM (Compact Disk Read Only Memory), an MO (Magneto-Optical disk), a DVD (Digital Versatile This includes any "portable physical media" such as a Blu-ray (registered trademark) Disc, and a Blu-ray (registered trademark) Disc.

A "program" is a data processing method written in any language or description method, and may be in any format, such as source code or binary code. Note that a "program" is not necessarily limited to a single configuration, but also includes a distributed configuration consisting of multiple modules or libraries, and a program that works in conjunction with a separate program, such as an OS, to achieve its function. Note that the specific configuration and reading procedure for reading a recording medium in each device shown in the embodiments, as well as the installation procedure after reading, can use well-known configurations and procedures.

The various databases stored in the memory unit are storage devices such as RAM, ROM, etc., fixed disk devices such as hard disks, flexible disks, and optical disks, and store various programs, tables, databases, and web page files used for various processes and providing websites.

The manufacturing instruction data generating device 100 may be configured as an information processing device such as a known personal computer or workstation, or may be configured as the information processing device to which any peripheral device is connected. The manufacturing instruction data generating device 100 may be realized by implementing software (including programs or data, etc.) that causes the device to realize the processing described in this embodiment.

Furthermore, the specific form of distribution and integration of the devices is not limited to that shown in the figures, and all or part of them can be functionally or physically distributed and integrated in any unit depending on various additions or functional loads. In other words, the above-mentioned embodiments can be implemented in any combination, or the embodiments can be implemented selectively.

The present invention is useful, for example, for material processing manufacturers, and is particularly useful for steel material processing manufacturers and meat processing manufacturers.

100 Manufacturing instruction data generating device 102 Control unit
102a Process pattern acquisition unit
102b Process acquisition department
102c Manufacturing location acquisition department
102d Lead time acquisition unit
102e Work start date calculation unit
102f Stock location acquisition unit
102g Manufacturing instruction data generating unit 104 Communication interface unit 106 Storage unit
106a Product master
106b Specification master
106c Process master
106d Process pattern master
106e Factory-by-process manufacturing location allocation master
106f Manufacturing location master
106g Warehouse LT Master
106h Calendar Master
106i Order Data
106j Planning Data
106k Manufacturing instruction data 108 Input/output interface unit 112 Input device 114 Output device 200 Server 300 Network

Claims (7)

A manufacturing instruction data generating device including a control unit and a storage unit,
The storage unit includes:
a specification master including product identification data for identifying a product and process pattern identification data for identifying a pattern of a combination of processes for manufacturing the product;
a process pattern master including the process pattern identification data, process identification data for identifying the process, and a target value of a finished product for each of the processes;
an allocation master including a general area to which a manufacturing location, which is a location where the product is manufactured, belongs, the process identification data, the range of the target value, and the manufacturing location;
A manufacturing location master including the manufacturing location and a reference inventory location;
is stored,
The control unit is
a process pattern acquisition means for acquiring process pattern identification data associated with the product identification data in the source data including the product identification data and the general area from the specification master;
a process acquisition means for acquiring process identification data and a target value associated with the process pattern identification data acquired by the process pattern acquisition means from the process pattern master;
a manufacturing location acquisition means for acquiring, from the allocation master, a manufacturing location that is linked to the general area in the source data, that is linked to the process identification data acquired by the process acquisition means, and that is linked to the range to which the target value acquired by the process acquisition means belongs;
a manufacturing instruction data generating means for generating manufacturing instruction data including at least the commodity identification data in the source data, the process identification data and the target value acquired by the process acquisition means, and the manufacturing location acquired by the manufacturing location acquisition means;
an inventory location acquisition means for acquiring, for each process in the manufacturing instruction data, a reference inventory location associated with the manufacturing location acquired by the manufacturing location acquisition means from the manufacturing location master, and further acquiring, for each process in the manufacturing instruction data, an inventory issuing location from which inventory is removed when manufacturing starts and an inventory recording location from which inventory is recorded when manufacturing is completed, based on the acquired reference inventory location;
Equipped with
The manufacturing instruction data generating means
storing the reference stock location, the stock issuing location and the stock recording location acquired for each process by said stock location acquisition means in said manufacturing instruction data;
A manufacturing instruction data generating device comprising: The storage unit includes:
A manufacturing location master including the manufacturing location and a lead time required for work at the manufacturing location is further stored;
The control unit is
a lead time acquisition means for acquiring, from the manufacturing location master, a lead time associated with the manufacturing location acquired by the manufacturing location acquisition means for each process in the manufacturing instruction data;
The manufacturing instruction data generating means
storing the lead time acquired for each process by said lead time acquisition means in said manufacturing instruction data;
2. The manufacturing instruction data generating device according to claim 1, The control unit is
Calculating a scheduled start date of the final process in the manufacturing instruction data by subtracting the lead time for the final process acquired by the lead time acquisition means from a manufacturing delivery date of the product;
a scheduled work start date calculation means for calculating scheduled work start dates from the process immediately preceding the final process to the first process in the manufacturing instruction data by subtracting the lead time for each process acquired by the lead time acquisition means from the calculated scheduled work start date for the process immediately following the final process,
The manufacturing instruction data generating means
storing the scheduled work start date of each process calculated by said scheduled work start date calculation means in said manufacturing instruction data;
3. The manufacturing instruction data generating device according to claim 2, The source data is order data or production plan data;
4. The manufacturing instruction data generating device according to claim 1 , wherein: Used by material processing manufacturers,
The target value is a target size of the material after the material is processed in each step;
5. The manufacturing instruction data generating device according to claim 1 , A manufacturing instruction data generation method executed by an information processing device having a control unit and a storage unit,
The storage unit includes:
a specification master including product identification data for identifying a product and process pattern identification data for identifying a pattern of a combination of processes for manufacturing the product;
a process pattern master including the process pattern identification data, process identification data for identifying the process, and a target value of a finished product for each of the processes;
an allocation master including a general area to which a manufacturing location, which is a location where the product is manufactured, belongs, the process identification data, the range of the target value, and the manufacturing location;
A manufacturing location master including the manufacturing location and a reference inventory location;
is stored,
Executed by the control unit,
a process pattern acquisition step of acquiring, from the specification master, process pattern identification data associated with the product identification data in the source data including the product identification data and the general area;
a process acquisition step of acquiring, from the process pattern master, process identification data and a target value associated with the process pattern identification data acquired in the process pattern acquisition step;
a manufacturing location acquisition step of acquiring, from the allocation master, a manufacturing location that is linked to the general area in the source data, that is linked to the process identification data acquired in the process acquisition step, and that is linked to the range to which the target value acquired in the process acquisition step belongs;
a production instruction data generating step of generating production instruction data including at least the commodity identification data in the source data, the process identification data and the target value acquired in the process acquisition step, and the production location acquired in the production location acquisition step;
an inventory location acquisition step of acquiring, for each process in the manufacturing instruction data, a reference inventory location associated with the manufacturing location acquired in the manufacturing location acquisition step from the manufacturing location master, and further acquiring, for each process in the manufacturing instruction data, an inventory issuing location which is a location for removing inventory when manufacturing starts and an inventory recording location which is a location for recording inventory when manufacturing is completed, based on the acquired reference inventory location;
Including,
The manufacturing instruction data generating step includes:
storing the reference stock location, the stock issuing location, and the stock recording location acquired for each process in the stock location acquisition step in the manufacturing instruction data;
A manufacturing instruction data generation method comprising: A manufacturing instruction data generation program to be executed by an information processing device having a control unit and a storage unit,
The storage unit includes:
a specification master including product identification data for identifying a product and process pattern identification data for identifying a pattern of a combination of processes for manufacturing the product;
a process pattern master including the process pattern identification data, process identification data for identifying the process, and a target value of a finished product for each of the processes;
an allocation master including a general area to which a manufacturing location, which is a location where the product is manufactured, belongs, the process identification data, the range of the target value, and the manufacturing location;
A manufacturing location master including the manufacturing location and a reference inventory location;
is stored,
To cause the control unit to execute
a process pattern acquisition step of acquiring, from the specification master, process pattern identification data associated with the product identification data in the source data including the product identification data and the general area;
a process acquisition step of acquiring, from the process pattern master, process identification data and a target value associated with the process pattern identification data acquired in the process pattern acquisition step;
a manufacturing location acquisition step of acquiring, from the allocation master, a manufacturing location that is linked to the general area in the source data, that is linked to the process identification data acquired in the process acquisition step, and that is linked to the range to which the target value acquired in the process acquisition step belongs;
a production instruction data generating step of generating production instruction data including at least the commodity identification data in the source data, the process identification data and the target value acquired in the process acquisition step, and the production location acquired in the production location acquisition step;
an inventory location acquisition step of acquiring, for each process in the manufacturing instruction data, a reference inventory location associated with the manufacturing location acquired in the manufacturing location acquisition step from the manufacturing location master, and further acquiring, for each process in the manufacturing instruction data, an inventory issuing location which is a location for removing inventory when manufacturing starts and an inventory recording location which is a location for recording inventory when manufacturing is completed, based on the acquired reference inventory location;
Including,
The manufacturing instruction data generating step includes:
storing the reference stock location, the stock issuing location, and the stock recording location acquired for each process in the stock location acquisition step in the manufacturing instruction data;
A manufacturing instruction data generation program comprising: