JP2000094276A - Stockpile plan making device and stockpile plan making method in stock-supply type production system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the article shortage totally including the products other than good sale products, by developing the stockpile plan in the article units of the good sale products. SOLUTION: This stockpile plan making device is provided with a weight converter 2 to convert the forcast sales of all the season plans to the weight at each month; a comparing member 3 to compare the converted weight and the production capacity of a production equipment; a necessary stockpile amount calculator 4 to calculate the weight of the excessive part as the necessary stockpile in this season when there is a month in which the converted weight exceeds the production capacity as the result of the comparison, while to decide the stockpile starting month from the production remaining power of the manth when the production capacity is low, and to calculate the necessary stockpile amount of the month unit from the number of monthes from the stockpile starting month to this month; a developer 5 to develop the calculated necessary stockpile amount of the month unit, to the article units of plural stockpile object products selected depending on the sales results in the former season; and a stockpile plan making member 6 to add the necessary stockpile amount of the month unit of each developed article number, to a normal production plan.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inventory replenishment type production system which is a type of production system for controlling production of a group of products for which demand is difficult to predict so as not to be out of stock. TECHNICAL FIELD The present invention relates to a storage plan creation device and a storage plan creation method in an inventory replenishment type production system in which a hot-selling product is stored in advance so as to prevent out-of-stock during a busy season.

[0002]

2. Description of the Related Art Hitherto, there has been provided a term production plan creating system for creating a highly accurate term production plan in consideration of the manufacturing restrictions of a factory and for creating a stock plan for each month and product number (Japanese Patent Application Laid-Open No. Hei 7 (1994)). -31801 publication).

[0003] This production plan creation system for each term,
A sales plan collection unit that collects monthly sales plan data, a sales plan automatic allocation unit that automatically allocates production to factory production lines based on the collected sales plan data, and a sales plan automatic A storage plan registering section for registering a surplus sales plan amount that cannot be allocated in the allocation section as a storage plan to be produced ahead of schedule.

[0004]

That is, the conventional period production plan creation system develops a production plan in units of monthly product numbers based on the sales plan of the period, and generates a surplus sales plan (ie,
Products that have a product number that is planned to be produced (sold) in excess of production capacity) are manufactured ahead of schedule, so that they can respond to months with a large number of shipments.

[0005] However, the characteristics of the product are (1) short life cycle, (2) sales are greatly influenced by consumer's taste and fashion, and (3) sales are only caused by different colors and sizes even in the same shape. In the case of consumables having characteristics such as a large difference, the stockpiling plan specified by the product number has large hits and misses, and it is difficult to make a term plan for each product number. For this reason, there is a problem that the term plan must be set for each product group (bucket, basin, ...). for that reason,
Looking at the period or year, even if stockpiling becomes necessary in connection with the efficiency of production facilities, it is not clear what to make, how much, and when.

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem. The object of the present invention is to develop a stockpiling plan into product number units of a hot selling product, so that not only the hot selling product but also other products are sold. An object of the present invention is to provide a stockpiling plan creating device and a stockpiling plan creating method in a stock replenishment type production system in which a production opportunity for a product is increased so as to prevent a total out of stock.

[0007]

According to a first aspect of the present invention, there is provided a stockpiling plan creator for a stock replenishment type production system, comprising: From the term plan, calculate the sales forecast amount of the entire term plan, and use the weight conversion means to convert the calculated sales forecast amount to monthly weight using the weight unit price results of the previous term. Means for comparing the calculated monthly weight with the monthly production capacity of the production equipment, and as a result of the comparison, if there is a month in which the weight-converted weight exceeds the production capacity, , Calculate the weight of the surplus as the required storage amount for the current term, determine the storage start month from the available capacity of the month before the current month and below the production capacity, and from this storage start month to the current month Months of From the required storage amount, a required storage amount calculating means for calculating a required storage amount on a monthly basis, and a required storage amount on a monthly basis calculated by the required storage amount calculating means are selected based on the sales results of the previous term. Means for expanding a plurality of stockpiled products into product numbers, and a stockpiling plan for adding a necessary storage amount on a monthly basis for each product number developed by the spreading means to a normal production plan for each month of the stockpiling period. And a storage plan creating means to be created.

According to a second aspect of the present invention, there is provided an apparatus for creating a stockpile plan in an inventory replenishment type production system according to the first aspect, wherein the expanding means includes a part number of each part number based on the sales results of the previous term. In addition to arranging the products in descending order of the shipment volume, the products are ranked according to a predetermined quantity from the top, and the product of the product number belonging to the highest rank is selected as the product to be stockpiled.

According to a third aspect of the present invention, there is provided a method for creating a stockpiling plan in a stock replenishment type production system, comprising: Is calculated, and the calculated sales forecast amount is converted into a monthly weight using the weight unit price in the previous term, and the weight-converted monthly weight is compared with the monthly production capacity of the production equipment, As a result of the comparison, if there is a month in which the weight-converted weight exceeds the production capacity, the excess weight is calculated as the necessary storage amount for the current term, The storage start month is determined from the production capacity of the month that is less than the month, the necessary storage amount is calculated on a monthly basis from the number of months from the storage start month to the current month and the required storage amount, and the calculated monthly storage amount is calculated. The necessary stockpiled amount was sold in the previous year Create a stockpiling plan that expands to the stock number of products selected for stockpiling based on performance, and adds the required monthly storage amount for each of the developed stock numbers to the normal production plan for each month during the stockpiling period Is what you do.

According to a fourth aspect of the present invention, there is provided a method for preparing a stockpiling plan in a stock replenishment type production system, comprising the steps of: Based on the sales performance of the previous term, the shipment volume of each product number is arranged in descending order based on the sales performance of the previous term, and the product is ranked by dividing it by a predetermined quantity from the top, The product of the product number belonging to the highest rank is selected as the stock target product.

[0011]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram of an entire system including a stockpiling plan creating apparatus in a stock replenishment type production system according to the present invention.

The storage plan creation device of the present invention comprises a parameter calculation unit 1, a weight conversion unit 2, a comparison unit 3, a necessary storage amount calculation unit 4, a development unit 5, and a storage plan creation unit 6. The parameter calculation unit 1 includes a data server 1
1 is input via the data server 11 to the weight conversion unit 2, and the sales plan data is input to the development unit 5 via the data server 11. Actual data has been entered. The data server 11 receives inventory actual data, shipping actual data, and received order data from the factory host computer 12.

The parameter calculation section 1 calculates various parameter values such as a standard stock, a minimum lot, and a replenishment point for all product numbers based on the shipment result data of the previous term.

The weight conversion unit 2 calculates a sales forecast amount for the entire term plan from a term plan for each product group in which a plurality of types of products are aggregated for each application, and calculates the calculated sales forecast amount for the weight unit price in the previous term. Is used to convert to monthly weight.

The comparing section 3 compares the monthly weight converted by the weight converting section 2 with the monthly production capacity of the production equipment.

If there is a month in which the weight-converted weight exceeds the production capacity as a result of the comparison in the comparison section 3, the necessary storage amount calculation section 4 calculates the weight of the excess weight in the current term. In addition to calculating as the necessary storage amount, the storage start month is determined from the available capacity of the month before the current month and below the production capacity, and the month from the storage start month to the current month and the required storage amount Calculate the required storage amount of the unit.

The developing unit 5 develops the required storage amount on a monthly basis calculated by the required storage amount calculating unit 4 into product number units of a plurality of storage target products selected based on the sales results of the previous term.

The stock plan creating unit 6 creates a stock plan by adding the required stock amount on a monthly basis for each product number developed by the developing unit 5 to a normal production plan for each month of the stock period.

Next, with regard to the processing of creating a stock plan in the stock plan creating apparatus having the above configuration, an example of the development of the term plan shown in FIG. 2 and an example of the calculation result of the stock number to be stocked and the stock amount in the stock number shown in FIG. The description will be made with reference to an appropriate case.

First, when the sales department issues a sales plan,
Based on the sales plan, the weight conversion unit 2 calculates the sales forecast amount of the entire period plan from the period plan for each product group in which a plurality of types of products are aggregated for each application. In the example shown in FIG. 2, as a result of summing the sales forecast amounts for each month for the six months from April to September, the sales forecast amount for the entire term plan is “3,633,60”.
0 (unit: 1,000 yen) ". In addition, the weight unit performance calculated based on the sales performance in the previous period (in this example, from October of the previous year to March of the current year) is “1,200
(Unit: Thousand yen) ", the weight conversion unit 2 divides the estimated sales amount for each month (April to September) by the actual weight unit price and converts the amount into the weight for each month. .

The comparison unit 3 compares the weight of each month converted by the weight conversion unit 2 with the monthly production capacity of the production equipment (540 t / month in this example) and calculates the difference. Calculate as surplus. In this example, there is production capacity from April to August, but since September is a busy season, the production capacity is minus (-177t).

As a result of the comparison by the comparing unit 3, the necessary stock amount calculating unit 4 determines that the converted weight in September (717 t) exceeds the production capacity (540 t / month), and Is calculated as the required storage amount for the current term (177 t). In addition, the necessary stockpiling amount calculation unit 4 determines the stockpiling start month from the production capacity of each month before September. That is, looking at the bottom column of FIG. 2 in which the production surplus has been cumulatively added from August to April, if it goes up to May, the accumulated production surplus (274t) is the necessary stockpiling amount (274t). 177t), so if stockpiling using production capacity is started in May, the shortfall in September (177t) will be covered.

For this reason, the necessary storage amount calculating section 4 calculates the required storage amount (177t) from the number of months (4 months) from the storage start month (May) to the month before the current month (August). The required storage amount on a monthly basis is calculated, and the developing unit 5 compares the required storage amount on a monthly basis calculated by the required storage amount calculating unit 4 with a plurality of storage target products selected based on the sales performance in the previous period. Expand to product number units.

Here, the calculation of the required storage amount on a monthly basis by the required storage amount calculation unit 4 and the development of the product number to be stored by the development unit 5 in units of product numbers will be described with reference to a calculation example shown in FIG. I do.

First, regarding the selection of products to be stockpiled, in the present embodiment, based on the sales results of the previous term, the shipment volume of each product number is arranged in descending order, and the rank is divided by a predetermined quantity from the top. Then, the product of the product number belonging to the highest rank is selected as the product to be stockpiled. That is,
The PQ analysis is performed from the shipment amount based on the sales performance data of the previous term, and the products of each product number are classified into, for example, three ranks of A, B, and C. That is, the products are arranged in descending order of the shipment volume, and rank A is ranked from the upper side to, for example, 50%.
Up to 0% is classified into B rank, and up to 100% (that is, all remaining) is classified into C rank. Then, the product of the A rank is selected as the storage target product. This is because if the product of rank A is set as a storage target product, there is a high possibility that the product will be shipped as soon as possible even if the product is stored due to a large amount of shipment.

In the example shown in FIG. 3, the products to be stored are:
31 items of the product numbers AAAA1 to DDDD1 are selected. Therefore, the shipping weight is calculated by multiplying the shipment results of these stockpiled products in the previous term by the unit weight. And
The weight ratio of each part number is obtained by dividing the shipping weight of each part number by the total amount of the shipping weight (1020.3 t in this example). For example, looking at the product number AAAA1,
0.04 (actually, 44.3 ÷ 1020.3 = 0.0
434186).

When the weight ratio of each product number is obtained in this manner, the stockpiling weight of each product number is obtained from the weight ratio by developing the required storage amount (177t) of the current term obtained this time. That is, the stockpiling weight is obtained for each product number by multiplying the necessary stockpiling amount (177t) by the weight ratio. For example, looking at the product number AAAA1, 177
(T) × 0.04 = 7.08. However, since the numerical value shown in FIG. 3 indicates the reserve weight calculated based on the correct weight ratio (0.0434186), the actual calculation is 177 (t) × 0.0434186 = 7.6850.
922, and the value obtained by truncating the third digit after the decimal point (7.
68).

As described above, when the stockpiled weight for each product number is obtained, the stockpiled weight is divided by the unit weight to obtain the stockpiled number for the current term, and the obtained stockpiled number is divided into the stockpiling period of four months (May. From August to August) to seek monthly stockpiling. For example, looking at the product number AAAA1, the stockpile weight is 7.68 (t), and the unit weight is 3.20 (kg).
Therefore, 7680 (kg) ÷ 3.20 (kg) = 2
400 (pieces). However, since the numerical value shown in FIG. 3 indicates the number of stocks in the current period calculated based on the accurate stock weight (7.6850922), the actual calculation is 76
85.0922 / 3.20 = 2401.5913, which is a value (2401) obtained by truncating the decimal part. Then, when the 2401 pieces are divided by 4 (months), which is the stockpiling period, the monthly stocking (required stocking amount per month) of the product number AAAA1 is 600 pieces (2401 ÷ 4).

The monthly stocks of the products from the product numbers AAAA2 to DDDD1 are also calculated in the same manner as in the case of the product number AAAA1.

In the example of the calculation result shown in FIG. 3, the reference stock of each product number is also written beside the monthly stock. The reference stock is a value calculated by the parameter calculation unit 1. Since various methods for obtaining the reference stock, the minimum lot, the replenishment point, and the like have been conventionally proposed, detailed description thereof will be omitted. Further, in the above description, at the stage where the required storage amount per period is calculated, the required storage amount per unit is expanded to the required storage amount per unit, and thereafter, the required storage amount per month per unit number is expanded. After calculating the required storage amount for each period, the required storage amount for each month is calculated, and then the required storage amount for each product number is expanded to the same result.

The stock plan creating unit 6 creates a stock plan in which the monthly stock for each product number developed by the developing unit 5 is added to the normal production plan for each month of the stock period.

Here, a production amount calculation method when a production method called stockpiling is added to the inventory replenishment type production method will be described with reference to FIG.

A normal production request is obtained by the following expression: when the replenishment point ≧ the inventory amount, the required production amount = the standard inventory−the actual inventory. On the other hand, if the stockpiling is set so that the monthly stockpiled for each product number developed as shown in FIG.
When [replenishment point + stock setting (monthly stock)] ≧ real stock, the required production quantity = (base stock-actual stock) + stock setting (month stock).

At this time, if the production process has a margin, the production amount to be produced is produced up to the set amount. If there is no margin, only the standard stock (standard stock-actual stock) is produced. In addition, there is no room to produce all of the stockpiling setting, but if there is some margin, the stock is produced as the stockpiling amount.

That is, ordinary stockpiling refers to a method of accumulating stockpiling to achieve a total stockpiling plan amount. In the present embodiment, [replenishment point + stockpiling setting ( Monthly stock)] ≧ Calculate the actual stock, and if the condition is satisfied, calculate the required production amount of the normal stock and the stock. The planning cycle is set to three days with a margin of one day, since it takes two days for lead time for procurement of components. In other words, every three days, [replenishment point + stockpiling setting (monthly stockpiling)] ≧ real stock is determined, and if the condition is satisfied, the required production amount for the normal stock and the stockpiled stock is calculated.

In this embodiment, inventory is reserved for the stock of the product to be stockpiled, and is treated the same as normal stock. That is, the storage in the present embodiment only means storing when there is room, and it is not always necessary to store the storage up to the set storage amount (that is, 177 t) as of September. . The purpose is to reduce the amount of production of products to be stockpiled during the busy season, thereby increasing the production opportunities for other products to be produced with the same equipment, and reducing the total out-of-stock.

[0038]

According to the stockpiling plan making apparatus and the stockpiling plan making method in the inventory replenishment type production system of the present invention, in the case of a product whose sales forecast is difficult to make, the production capacity exceeds the shipment at the end of the term. In such a case, by selecting a product with a large shipment volume as a product to be stockpiled and making it when it can be made, the production requirement of the product to be stockpiled during the busy season is reduced, so that the same equipment can be used. Since the production opportunities for other products to be produced are increased, the total out-of-stock can be reduced. That is, by leveling out production opportunities and increasing production opportunities for busy machines, it is possible to prevent the entire product from being out of stock.

[Brief description of the drawings]

FIG. 1 is a configuration diagram of an entire system including a stockpiling plan creating device in a stock replenishment type production system of the present invention.

FIG. 2 is an explanatory diagram summarizing a development example of a term plan in a list format.

FIG. 3 is an explanatory diagram summarizing in a list form an example of a storage target product number and a calculation result of a storage amount for each product number.

FIG. 4 is an explanatory diagram showing a state of a change in stock when a stockpiling production method according to the present invention is adopted.

[Explanation of symbols]

 1 Parameter calculation section 2 Weight conversion section 3 Comparison section 4 Required storage amount calculation section 5 Development section 6 Storage plan creation section

Claims (4)

[Claims] 1. A sales forecast amount for the entire term plan is calculated from a term plan for each product group in which a plurality of types of products are aggregated for each application, and the calculated sales forecast amount is calculated using the weight unit price results of the previous term. Weight conversion means for converting the weight per month, comparison means for comparing the monthly weight converted by the weight conversion means with the monthly production capacity of the production equipment, and a result of the comparison by the comparison means, If there is a month in which the converted weight exceeds the production capacity, the extra weight is calculated as the necessary stock for the current term, and the month before the current month and the production capacity is lower. A required storage amount calculating means for determining a required storage amount on a monthly basis from the number of months from the storage start month to the current month and the required storage amount, and determining the required storage amount; Calculated by means Means for expanding the required monthly storage amount into product numbers for a plurality of products to be stored selected based on the sales results of the previous fiscal year, and monthly storage requirements for each product number developed by this development means A storage plan creating means for creating a storage plan for adding a quantity to a normal production plan for each month of the storage period; 2. The developing means arranges the shipment amount of each part number in descending order based on the sales results of the previous term, and performs a rank division by a predetermined quantity from a higher rank, and determines a part number belonging to the highest rank. The storage plan creation device and the storage plan creation device in the inventory replenishment type production system according to claim 1, wherein the product is selected as a storage target product. 3. A sales forecast amount for the entire term plan is calculated from a term plan for each product group in which a plurality of types of products are aggregated by application, and the calculated sales forecast amount is calculated using the weight unit price results of the previous term. And then compare the weight of each month converted into the weight with the monthly production capacity of the production equipment. As a result of the comparison, if there is a month in which the weight converted weight exceeds the production capacity Is calculated as the required storage amount for the current term, and the storage start month is determined from the available capacity of the month before the current month and below the production capacity. From the number of months up to the current month and the required storage amount, a required storage amount on a monthly basis is calculated, and the calculated required storage amount on a monthly basis is calculated for a plurality of storage target products selected based on the sales performance in the previous term. Expand by product number A stockpiling plan creation method in a stock replenishment type production method, wherein a stockpiling plan is created by adding a necessary stockpiling amount of each month for each product number to a normal production plan of each month of the stockpiling period. 4. When the calculated required storage amount on a monthly basis is expanded into product number units of a plurality of stockpiled products selected based on the sales performance in the previous term, the shipment volume of each product number based on the sales performance in the previous term. 4. The storage plan in the inventory replenishment type production system according to claim 3, wherein the products are arranged in the descending order, and are classified according to a predetermined quantity from the upper rank, and the products of the product numbers belonging to the highest rank are selected as the products to be stored. How to make.