1. A component order system, comprising: a component order device configured to generate component order information; and a production plan system configured to transmit production plan information which manages a production plan of a product to the component order device, wherein the component order device comprises an arrangement probability estimation unit for each process configured to calculate arrangement probability of a component for each manufacturing process in a product manufactured in the past, a number estimation unit when using a component configured to calculate the number when using the component in the product manufactured in the past, a prediction unit for the number of uses for each product configured to define the arrangement probability of the component corresponding to process progress of the product to be specified from the production plan information as use probability of the component, and configured to predict the number of uses of the component based on the use probability and the number when using the component, and a component order information generation unit configured to calculate the number of orders of the component based on the number of uses of the component and a lot size which is a minimum order unit of the component, and configured to 61 generate component order information including the calculated number of orders.

2. The component order system according to claim 1, wherein the prediction unit for the number of uses for each product specifies a manufacturing process start date of the product to be specified using the production plan information as a use date of the component, and the component order information generation unit calculates a delivery deadline of the component based upon the specified use date of the component, calculates an order date of the component based upon a procurement lead time of the component, calculates an order amount of the component based upon the number of orders of the component, the lot size thereof, and a unit price thereof, and generates the component order information which the delivery deadline, the order date, the order amount, and the number of orders are associated with.

3. The component order system according to claim 2, further comprising: a stock transition prediction unit configured to specify the number of orders and the delivery deadline 62 of the component order information as the number of warehousing of the component and a warehousing date thereof, respectively, specify the number of uses and the use date of the component as the number of delivery of the component and a delivery date thereof, respectively, and calculate transition of the number of stocks of the component based on a difference between the number of warehousing of the component and the number of delivery thereof.

4. The component order system according to claim 3, further comprising: an output process unit configured to generate display screen information of the component order information.

5. The component order system according to claim 4, wherein the output process unit generates display screen information in which the number of stocks of the component is graphed in time series.

6. The component order system according to claim 4, wherein the output process unit generates display screen information of prediction information on the number of uses 63 for each product which at least the product and the component, the process progress, the use probability, and the number of uses are associated with.

7. The component order system according to claim 6, further comprising: an input reception unit configured to receive a change with respect to the number of uses of the displayed prediction information on the number of uses for each product, wherein when the input reception unit receives the change of the number of uses, the component order information generation unit regenerates the component order information using the inputted number of uses of the component after the change.

8. The component order system according to claim 7, wherein the stock transition prediction unit recalculates the number of stocks using the inputted number of uses of the component after the change and the regenerated component order information.

9. The component order system according to claim 2, wherein the component order information generation unit generates component order information including the order date, 64 the number of orders, the order amount, and the delivery deadline which are obtained for each pattern in which any one of the procurement lead time, the lot size, and the unit price is varied.

10. The component order system according to claim 9, further comprising: an output process unit configured to calculate an total amount of the order of the component and an average amount of stock per day using the component order information including the items which are obtained for each pattern, and configured to generate display screen information of the total amount of order and the average amount of stock.

11. A component order device, comprising: an arrangement probability estimation unit for each process configured to calculate arrangement probability of a component for each manufacturing process in a product manufactured in the past; a number estimation unit when using a component configured to calculate the number when using the component in the product manufactured in the past; a prediction unit for the number of uses for each product configured to define the arrangement probability of the component corresponding to process progress of the product as 65 use probability of the component, and configured to predict the number of uses of the component based upon the use probability and the number when using the component; and a component order information generation unit configured to calculate the number of orders of the component based upon the number of uses of the component and a lot size which is a minimum order unit of the component, and configured to generate component order information including the calculated number of orders.

12. The component order device according to claim 11, wherein the component order information generation unit calculates a delivery deadline of the component based upon a use date of the component which is specified by the prediction unit for the number of uses for each product, calculates an order date of the component based upon a procurement lead time of the component, calculates an order amount of the component based upon the number of orders of the component, the lot size thereof, and a unit price thereof, and generates the component order information which the delivery deadline, the order date, the order amount, and the number of orders are associated with.

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a component order system
and a component order device.
2. Description of Related Art
In JP-A-2014-130466, an item requirement prediction
device is described as follows: a pre-arrangement
determination unit of the item requirement prediction device
determines a pre-arrangement item based upon business
negotiation information acquired by an input unit; prediction
pattern information stored in a prediction pattern DB;
component configuration information stored in a component item
DB; purchase master information stored in a purchase mater DB;
and common stock information stored in a common stock DB. An
output unit outputs pre-arrangement information. A common
stock registration unit extracts unused components based on
order reception information, the component configuration
information, the pre-arrangement information, and registers
the extracted unused components in the common stock DB. A
pattern updating unit calculates an occurrence probability of
a definite specification with respect to a predetermined
specification based upon the order reception information and
2
the business negotiation information including business
negotiation identification information which is identical to
or is associated with work identification information included
in the order reception information, and updates the prediction
pattern information based upon the calculated result thereof.
For example, in the case of a product related to a social
infrastructure system such as a control board, and the like,
there exists an individual order reception design product which
designs a product configuration each time according to a
customer’s order and performs manufacturing by arranging
required components according to the design thereof. Such a
product cannot order components after confirming a component
configuration table (BOM: Bill OF Materials) to be used in
advance like a mass-produced product. Further, there also
exists a method of handling the above-mentioned drawback by
having various components in stock based upon an assumed
product specification, however, since the product
specifications of the individual order reception design
products are widely diverse, it may occur to have excessive
stock, thereby causing an increase in stock management cost
and deterioration of inventory assets. Therefore, it is
important to place an order with an appropriate quantity, and
to appropriately design a lot side, a unit price, and the like
when placing an order by predicting a type of necessary
component and the number of necessary components according to
3
a type, and the like of a product with high accuracy.
Here, an item requirement prediction device disclosed
in JP-A-2014-130466 calculates an occurrence probability of
a definite specification with respect to a predetermined
specification of a product, calculates a specification
probability of each component from component configuration
information in the definite specification, and performs a
pre-arrangement of the component. However, the item
requirement prediction device disclosed in JP-A-2014-130466
does not consider a component arrangement with respect to an
individual order reception design product in which a design
is performed while a product specification is confirmed step
by step and a required component is arranged.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of
the above-mentioned drawbacks and in an effort to provide a
component order system which is capable of predicting the
number of various components corresponding to process progress
such as a design, and the like with high accuracy in the
individual order reception design product in which a product
specification is confirmed step by step, and a design and a
component arrangement are performed.
The present invention includes a plurality of means for
solving at least a part of the above-mentioned drawbacks, and
4
examples of the plurality of means therefor will be hereinafter
described. A component order system according to one
embodiment of the present invention for solving the
above-mentioned drawbacks may include a component order device
which generates component order information, and a production
plan system which transmits production plan information for
managing a production plan of a product to the component order
device, wherein the component order device includes an
arrangement probability estimation unit for each process which
calculates arrangement probability of a component for each
manufacturing process in a product manufactured in the past;
a number estimation unit when using a component which
calculates the number when using the component in the product
manufactured in the past; a prediction unit for the number of
uses for each product which defines the arrangement probability
of the component corresponding to process progress of the
product to be specified from the production plan information
as use probability of the component, and which predicts the
number of uses of the component based upon the use probability
and the number when using the component; and a component order
information generation unit which calculates the number of
orders of the component based upon the number of uses of the
component and a lot size which is a minimum order unit of the
component, and which generates component order information
including the calculated number of orders.
5
A component order system according to the present
invention is capable of predicting the number of uses of various
components corresponding to process progress such a design,
and the like with high accuracy in an individual order reception
design product in which a product specification is confirmed
step by step, and a design and a component arrangement are
performed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating an example of a schematic
configuration of a component order system according to an
embodiment of the present invention;
FIG. 2 is a diagram illustrating an example of component
use record information according to an embodiment of the
present invention;
FIG. 3 is a diagram illustrating an example of process
order information according to an embodiment of the present
invention;
FIG. 4 is a diagram illustrating an example of component
arrangement information according to an embodiment of the
present invention;
FIG. 5 is a diagram illustrating an example of order
contract information according to an embodiment of the present
invention;
FIG. 6 is a diagram illustrating an example of
6
arrangement probability information for each process
according to an embodiment of the present invention;
FIG. 7 is a diagram illustrating an example of prediction
information on the number of uses for each product according
to an embodiment of the present invention;
FIG. 8 is a diagram illustrating an example of component
order information according to an embodiment of the present
invention;
FIG. 9 is a diagram illustrating an example of stock
transition information according to an embodiment of the
present invention;
FIG. 10 is a diagram illustrating an example of a hardware
configuration of a component order device according to an
embodiment of the present invention;
FIG. 11 is a diagram illustrating an input screen example
which receives a narrowing-down condition of a target product
according to an embodiment of the present invention;
FIG. 12 is a flowchart illustrating an example of a new
feature evaluation value updating process according to an
embodiment of the present invention;
FIG. 13 is a diagram illustrating an example of
production plan information according to an embodiment of the
present invention;
FIG. 14 is a flowchart illustrating details of a process
of estimating a component arrangement probability for each
7
process according to an embodiment of the present invention;
FIG. 15 is a diagram illustrating an example of the number
information when using a component according to an embodiment
of the present invention;
FIG. 16 is a flowchart illustrating details of a process
of predicting the number of components used for each product
according to an embodiment of the present invention;
FIG. 17 is a flowchart illustrating details of a process
of generating component order information according to an
embodiment of the present invention;
FIG. 18 illustrates an example of a display screen on
which output information according to an embodiment of the
present invention is displayed;
FIG. 19 is a diagram illustrating an example of a
schematic configuration of a component order system according
to another embodiment of the present invention;
FIG. 20 is a diagram illustrating an example of order
contract pattern information according to another embodiment
of the present invention;
FIG. 21 is a diagram illustrating an example of a
component order information generation process according to
another embodiment of the present invention;
FIG. 22 is a diagram illustrating an input screen example
which receives a narrowing-down condition of a target product
and a condition of an order contract pattern according to
8
another embodiment of the present invention;
FIG. 23 is a diagram illustrating an example of component
order information according to another embodiment of the
present invention;
FIG. 24 is a diagram illustrating an example of stock
transition information according to another embodiment of the
present invention; and
FIG. 25 illustrates an example of a display screen on
which output information according to another embodiment of
the present invention is displayed.
DESCRIPTION OF EMBODIMENTS
Hereinafter, a component order system according to
respective embodiments of the present invention will be
described with reference to the drawings.
[First Embodiment]
FIG. 1 is a diagram illustrating an example of a schematic
configuration of a component order system according to the
embodiment. The component order system includes a component
order device 100 and a production plan system 200. The
component order device 100 is a device which calculates the
predicted number of uses of various components to be used for
an individual order reception design product, generates
component order information 117, and presents the generated
component order information 117 to a user. The production plan
9
system 200 is a system which manages a production plan of a
product, and holds production plan information 201. The
component order device 100 is connected to the production plan
system 200 via a network N so as to be communicated with each
other, and acquires the production plan information 201 from
the production plan system 200 at a predetermined timing (for
example, during a component order information generation
process which will be described later). Further, the network
N is, for example, a public network such as the Internet, and
the like, a LAN (Local Area Network), a WAN (Wide Area Network),
or the like.
As illustrated in the drawing, the component order device
100 includes a storage unit 110, a calculation unit 120, and
a communication unit 130.
The storage unit 110 is a functional unit which stores
various information. Specifically, the storage unit 110
stores component use record information 111, process order
information 112, component arrangement information 113, and
order contract information 114 in advance as input information.
Further, the storage unit 110 stores arrangement probability
information for each process 115, prediction information on
the number of uses for each product 116, component order
information 117, and stock transition information 118, all of
which are generated in the component order information
generation process, as output information.
10
FIG. 2 is a diagram illustrating an example of the
component use record information 111. The component use
record information 111 is information which manages a use
record such as a type, the number of uses, and the like of a
component which was used in a product manufactured in the past.
Specifically, the component use record information 111
includes a record which a manufacturing number 111a, a product
code 111b, a component code 111c, the number of uses 111d, and
an arrangement process 111e are associated with.
The manufacturing number 111a is a number by which a
manufacturing work of a product is managed and identified. The
product code 111b is information which identifies a type of
a product to be manufactured. The component code 111c is
information which identifies a component used for the product
to be manufactured. The number of uses 111d is information
which indicates the number of uses of a component. The
arrangement process 111e is information which indicates a
process in which an arrangement of a component is performed
when manufacturing a product. For example, a record 111f is
information on a product of a type of a product code A01 managed
by a manufacturing number X010, and indicates that there is
a record of arranging 10 pieces of components of a component
code B001 in a process code D2. Further, as described later,
the process code is information which identifies a
manufacturing process of a product.
11
FIG. 3 is a diagram illustrating an example of the process
order information 112. The process order information 112 is
information which manages the manufacturing process and order
thereof which are required for designing and manufacturing a
product indicated by each product code. Specifically, the
process order information 112 includes a record in which a
product code 112a, a process code 112b, and process order 112c
are associated with each other.
The product code 112a is information which identifies
the type of the product to be manufactured, and is information
which is common to the product code 111b of the component use
record information 111. The process code 112b is information
which identifies the manufacturing process of the product.
Further, D1 to D3 of the process code 112b indicates a design
process of the product, and M of the process code 112b indicates
the manufacturing process of the product. The process order
112c is information which specifies the order of the associated
manufacturing processes. For example, FIG. 3 indicates that
in a manufacturing process in which the product of the type
of the product code A01 is manufactured, there are D1, D2, D3
and M and there are the first to the fourth process,
respectively in the process order.
FIG. 4 is a diagram illustrating an example of the
component arrangement information 113. The component
arrangement information 113 is information which manages
12
arrangement history of a component used for manufacturing a
product specified by an associated manufacturing number.
Specifically, the component arrangement information 113
includes a record in which a manufacturing number 113a, a
component code 113b, and an arrangement number 113c are
associated with each other.
The manufacturing number 113a is a number which manages
and identifies a manufacturing work of a product, and is
information common to the manufacturing number 111a of the
component use record information 111. The component code 113b
is information which identifies a component used for a product
to be manufactured, and is information common to the component
code 111c of the component use record information 111. The
number of arrangements 113c is information which indicates the
arrangement number of the components. For example, a record
113d indicates that 10 pieces of the components of the component
code B001 are arranged with respect to the manufacture of a
product managed by a manufacturing number Y010.
FIG. 5 is a diagram illustrating an example of the order
contract information 114. The order contract information 114
is information which manages an order contract with a supplier.
Specifically, the order contract information 114 includes a
record in which a component code 114a, a procurement lead time
114b, a lot size 114c, and a unit price 114d are associated
with each other.
13
The component code 114a is information which identifies
a component used for a product to be manufactured, and is
information common to the component code 111c of the component
use record information 111. The procurement lead time 114b
is information which indicates a lead time until a procured
component is put into a warehouse. The lot size 114c is
information which indicates a minimum unit when a component
is ordered. The unit price 114d is information which indicates
an order unit price of a component. For example, the record
114e indicates that with respect to the component of the
component code B001, a contract in which the procurement lead
time is 30 days, the lot size is 5 pieces, and the unit price
is 10K¥ is made with a supplier.
FIG. 6 is a diagram illustrating an example of the
arrangement probability information for each process 115. The
arrangement probability information for each process 115 is
information which manages arrangement probability of a
component corresponding to process progress of a product.
Specifically, the arrangement probability information for
each process 115 has a record in which a product code 115a,
a component code 115b, a process code 115c, and an arrangement
probability 115d are associated with each other.
The product code 115a is information which identifies
a type of a product to be manufactured, and is information
common to the product code 111b of the component use record
14
information 111. The component code 115b is information which
identifies a component used for a product to be manufactured,
and is information common to the component code 111c of the
component use record information 111. The process code 115c
is information which identifies a manufacturing process of the
product, and is information common to the process code 112b
of the process order information 112. The arrangement
probability 115d is information which indicates the
probability of arranging the component in an associated process.
For example, the record 115e indicates that the probability
of arranging the component of the component code B001 used for
the product of the product code A01 in a process code D1 is
60%.
FIG. 7 is a diagram illustrating an example of the
prediction information on the number of uses for each product
116. The prediction information on the number of uses for each
product 116 is information which manages the predicted number
of uses of a component to be used for each product, and the
like. Specifically, the prediction information on the number
of uses for each product 116 includes a record in which a
manufacturing number 116a, a product code 116b, a component
code 116c, process progress 116d, arrangement existence or
nonexistence 116e, use probability 116f, the number during the
use 116g, the number of uses 116h, and a use date 116i are
associated with each other.
15
The manufacturing number 116a is a number which manages
and identifies a manufacturing work of a product, and is
information common to the manufacturing number 111a of the
component use record information 111. The product code 116b
is information which identifies a type of a product to be
manufactured, and is information common to the product code
111b of the component use record information 111. The
component code 116c is information which identifies a component
used for a product to be manufactured, and is information common
to the component code 111c of the component use record
information 111. The process progress 116d is information
which identifies a progress state of the manufacturing process
of the product indicated by the product code, and is information
common to the process code 112b of the process order information
112. The arrangement existence or nonexistence 116e is
information which indicates whether or not a component is
arranged. Further, “existence” indicates that the component
is arranged, and “nonexistence” indicates that the component
is not arranged. The use probability 116f is information which
indicates the probability of using a component. The member
number during the use 116g is information which indicates the
number when using a member. The number of uses 116h is
information which indicates the predicted number of uses of
a component. The use date 116i is information which indicates
a use date of a component. For example, a record 116j indicates
16
that the product of the product code A01 managed by a
manufacturing number Y011 proceeds to D2 in the manufacturing
process; the component of the component code B001 which has
a possibility of being used is not arranged yet; the possibility
of using the associated component B001 is 50%; the number when
using the component is 10 pieces; the expected number of uses
is 5 pieces; and the estimated use date thereof is June 30.
FIG. 8 is a diagram illustrating an example of the
component order information 117. The component order
information 117 is information which manages an order of a
component to be used for manufacturing each product.
Specifically, the component order information 117 has a record
in which an order code 117a, a component code 117b, an order
date 117c, the number of orders 117d, an order amount 117e,
and a delivery deadline 117f are associated with each other.
The order code 117a is information which manages and
identifies each ordered content. The component code 117b is
information which identifies a component used for a product
to be manufactured, and is information common to the component
code 111c of the component use record information 111. The
order date 117c is information which indicates an order date
of a component. The number of orders 117d is information which
indicates the number of orders of a component. The order amount
117e is information which indicates an order amount of a
component. The delivery deadline 117f is information which
17
indicates a delivery deadline of an ordered component. For
example, a record 117g indicates that an order content managed
by an order code H011 is that 5 pieces of the components of
the component code B001 are scheduled to be ordered on May 30,
the order amount thereof is 50k¥, and the deadline is June 29.
FIG. 9 is a diagram illustrating an example of the stock
transition information 118. The stock transition information
118 is information which manages component stock transition
based on warehousing and delivery of each component.
Specifically, the stock transition information 118 has a record
in which a component code 118a, a warehousing or delivery
section 118b, the number of warehousing or delivery 118c, a
warehousing or delivery date 118d, and the number of stocks
118e are associated with each other.
The component code 118a is information which identifies
a component used for a product to be manufactured, and is
information common to the component code 111c of the component
use record information 111. The warehousing or delivery
section 118b is information which indicates the warehousing
or delivery section of a component. The number of warehousing
or delivery 118c is information which indicates the number of
warehousing or delivery of a component. The warehousing or
delivery date 118d is information which indicates a warehousing
date or a delivery date of a component. The number of stocks
118e is information which indicates the number of stocks
18
calculated from a difference between the warehousing of a
component and the delivery of a component. For example, a
record 118f indicates that 10 pieces of the components of the
component code B001 are put into a warehouse on June 24 and
the number of stocks at that time becomes 10 pieces.
Further, each information shown in FIGS. 2 to 9 is
information generated by the component order information
generation process.
Referring back to FIG. 1, the calculation unit 120
includes an input reception unit 121, an output process unit
122, an arrangement probability estimation unit for each
process 123, a number estimation unit when using a component
124, a prediction unit for the number of uses for each product
125, a component order information generation unit 126, and
a stock transition prediction unit 127.
The input reception unit 121 is a functional unit which
receives input information from a user via an input device such
as a keyboard and a mouse. Further, the input reception unit
121 acquires input information stored in the storage unit 110
in the component order information generation process which
will be described later. Additionally, the input reception
unit 121 transfers the acquired input information to a
corresponding functional unit of the calculation unit 120.
The output process unit 122 is a functional unit which
generates screen information to be displayed on a display
19
device. Specifically, the output process unit 122 generates
the screen information to be displayed on the display device
provided in the component order device 100.
The arrangement probability estimation unit for each
process 123 is a functional unit which generates the
arrangement probability information for each process 115 in
the component order information generation process which will
be described later.
The number estimation unit when using the component 124
is a functional unit which generates intermediate process
information in the component order information generation
process which will be described later.
The prediction unit for the number of uses for each
product 125 is a functional unit which generates the prediction
information on the number of uses for each product 116 in the
component order information generation process which will be
described later.
The component order information generation unit 126 is
a functional unit which generates the component order
information 117 in the component order information generation
process which will be described later.
The stock transition prediction unit 127 is a functional
unit which generates the stock transition information 118 in
the component order information generation process which will
be described later.
20
The communication unit 130 is a functional unit which
transmits and receives information to and from an external
device. Specifically, the communication unit 130 acquires the
production plan information 201 from the production plan system
200 at a predetermined timing.
Hereinafter, a functional block of the component order
device 100 will be described.
FIG. 10 is a diagram illustrating an example of a hardware
configuration of the component order device 100. The
component order device 100 is realized by a high-performance
information process device such as a server device.
As illustrated in the drawing, the component order device
100 includes an input device 301, a display device 302, an
external storage device 303, a calculation device 304, a main
storage device 305, a communication device 306, and a bus 307
by which the above-mentioned devices are electrically
connected to each other.
The input device 301 is a pointing device such as a
keyboard, a mouse, a touch panel, and the like. The display
device 302 is, for example, a liquid crystal display and an
organic display, and the like.
The external storage device 303 is a nonvolatile storage
device such as a so-called hard disk (Hard Disk Drive), an SSD
(Solid State Drive), a flash memory, or the like which are
capable of storing digital information.
21
The calculation device 304 is, for example, a CPU
(Central Processing Unit). The main storage device 305 is a
memory device such as a RAM (Random Access Memory), a ROM (Read
Only Memory), or the like.
The communication device 306 is a wired communication
device 306 which performs wired communication via a network
cable or a wireless communication device 306 which performs
wireless communication via an antenna. The communication
device 306 performs information communication with the
external device connected to the network N.
Further, the calculation unit 120 of the component order
device 100 is realized by a program which causes the calculation
device 304 to perform a process. The program is stored in the
main storage device 305 or the external storage device 303,
loaded on the main storage device 305 when executing the program,
and is executed by the calculation device 304. Further, the
storage unit 110 is realized by the main storage device 305
or the external storage device 303 or a combination thereof.
Additionally, the communication unit 130 is realized by the
communication device 306.
Further, each of the above-mentioned configurations,
functions, process units, process means, and the like of the
component order device 100 may be realized with hardware, for
example, by designing a part or all of them with an integrated
circuit, and the like. Further, the configurations and the
22
functions may be realized with software by interpreting and
executing a program in which the respective functions are
realized by the processor. Information such as a program, a
table, a file, and the like which realize the respective
functions can be placed in a storage device such as a memory,
a hard disk, an SSD, and the like, or a recording medium such
as an IC card, an SD card, a DVD, and the like.
Further, the hardware configuration of the component
order device 100 is not limited thereto, but may be configured
by using other hardware. For example, a device which receives
input and output through the internet may be adopted. Further,
the component order device 100 includes well-known elements
such as an OS (Operating System), middleware, an application,
and the like, all of which are not illustrated, and is
particularly provided with an existing process function for
displaying a GUI screen on an input and output device such as
a display, and the like.
Up to here, the hardware configuration of the component
order device 100 has been described.
[Description of Operation]
FIG. 11 is a flowchart illustrating an example of the
component order information generation process. The
associated process is started when the input reception unit
121 receives an execution instruction from a user. When
receiving the execution instruction of the component order
23
information generation process, the input reception unit 121
generates input screen information for receiving a condition
of a product which becomes a generation target of the component
order information 117 via the output process unit 122 and
displays the generated input screen information on the display
device 302.
FIG. 12 is a diagram illustrating an example of an input
screen 400 which receives a narrowing-down condition of a
target product. As illustrated in the drawing, the input
screen 400 displays input fields 401 and 402 for receiving a
manufacturing state and a process period as a narrowing-down
condition of a target product; a setting button 403 which
receives a setting instruction of a condition; a condition
display field 404 which displays a set condition; a deletion
button 405 which receives a deletion instruction of a record
in the condition display field; an execution button 406 which
receives an execution instruction of the component order
information generation process.
The input field of the manufacturing state 401 is
provided with a radio button 410 which selects any one of items
such as incompletion 407, completion 408, and all 409. Here,
the incompletion 407 is a condition selected when outputting
the component order information 117 of a product which is not
completed in manufacture, that is, a product including even
one incomplete process. Further, the completion 408 is a
24
condition selected when outputting the component order
information 117 of a product, all the processes of which are
completed. Further, the all 409 is a condition selected when
outputting the component order information 117 of a product,
the manufacturing state of which is incomplete and completed.
Further, the input field 402 of the process period is
provided with a pull-down button 411 for selecting a target
process and an input field 412 for inputting an execution period
of the selected target process.
When a condition desired by a user is inputted to the
input fields 401 and 402 of the manufacturing state and the
process period, and a setting button 403 is pressed down, an
inputted target process, and a start date and an end date of
the target process are displayed in the corresponding condition
display fields 404. Additionally, a selection check box which
receives selection of a record is correspondingly attached to
the condition display field 404.
For example, in the input screen example 400 in FIG. 1 2,
the narrowing-down condition of the target product indicates
that an execution period (or a scheduled execution period) of
a target process “D1” is included in “from April 1 to September
30” and indicates a product in which “an incomplete process”
remains.
Referring back to FIG. 11, when receiving input of a
predetermined condition with respect to the target product and
25
the execution instruction of the component order information
generation process, the input reception unit 121 starts the
associated process, and acquires the input information and the
production plan information 201 at step S100. Specifically,
the input reception unit 121 acquires the component use record
information 111, the process sequence information 112, the
component arrangement information 113, and the order contract
information 114 from the storage unit 110. Further, the input
reception unit 121 acquires the production plan information
201 from the production plan system 200 via the communication
unit 130.
FIG. 13 is a diagram illustrating an example of the
production plan information 201. The production plan
information 201 is information which manages a production plan
of a product. Specifically, the production plan information
201 has a record in which a manufacturing number 201a, a product
code 201b, a process code 201c, a process start date 201d, a
process end date 201e, and a completion record 201f are
associated with each other.
The manufacturing number 201a is a number which manages
and identifies a manufacturing work of a product, and is
information common to the manufacturing number 111a of the
component use record information 111. The product code 201b
is information which identifies a type of a product to be
manufactured, and is information common to the product code
26
111b of the component use record information 111. The process
code 201c is information which identifies a manufacturing
process of the product, and is information common to the process
code 112b of the process sequence information 112. The process
start date 201d is information which indicates a start date
of an associated process. The process end date 201e is
information which indicates an end date of an associated
process. The completion record 201f is information which
indicates whether the associated process is completed or
incomplete.
Referring back to FIG. 11, next, the arrangement
probability estimation unit for each process 123 estimates
component arrangement probability for each process at step
S110.
FIG. 14 is a flowchart illustrating details of a process
of estimating the component arrangement probability for each
process. When the process is started, the arrangement
probability estimation unit for each process 123 counts the
number of manufacturing cases in which a component is not used
at step S1100. Specifically, the arrangement probability
estimation unit for each process 123 specifies from the
production plan information 201 a record (for example, a record
201g) which executes the target process (for example, D1) in
a process period (for example, April 1 to September 3 0 ) , which
is inputted as the narrowing-down condition of the target
27
product. Further, the arrangement probability estimation
unit for each process 123 executes the following process for
each specified record.
The arrangement probability estimation unit for each
process 123 specifies the product code (for example, A01)
associated with the specified record 201g. Further, the
arrangement probability estimation unit for each process 123
specifies the component code (for example, B001) which is
associated with the specified product code (for example, A01)
from the component use record information 111. Additionally,
the arrangement probability estimation unit for each process
123 executes the following process for each specified component
code.
The arrangement probability estimation unit for each
process 123 calculates the total number of cases (4 cases) of
manufacturing numbers (X012, X015, X017, and X019) whose number
of uses of the specified component code (B001) is 0 using the
component use record information 111.
Next, the arrangement probability estimation unit for
each process 123 specifies the process sequence corresponding
to the specified product code using the process sequence
information 112 at Step S1110. Specifically, the arrangement
probability estimation unit for each process 123 specifies the
process codes (D1, D2, D3, and M) of the process sequence
information 112 and the process sequence (1 to 4) thereof, the
28
codes and the order corresponding to the specified product code
(A01).
Next, the arrangement probability estimation unit for
each process 123 counts arrangement records after each
corresponding process at step S1120. Specifically, the
arrangement probability estimation unit for each process 123
calculates the total number of cases (6 cases) of manufacturing
numbers (X010, X011, X013, X014, X016, X018) which arrange the
component (B001) in or after the first process (D1) of the
specified product code (A01) using the component use record
information 111.
Next, the arrangement probability estimation unit for
each process 123 calculates the arrangement probability for
each process at step S1130. Specifically, for each
corresponding process, the arrangement probability estimation
unit for each process 123 calculates a value which is obtained
by dividing the total number of cases of manufacturing numbers
which arrange components by (the number of manufacturing
numbers with the number of uses “0” + the total number of cases
of manufacturing numbers which arrange components in or after
the corresponding process) as the component arrangement
probability for each process. For example, the arrangement
probability of the component (B001) in or after the process
D1 becomes 6/(4+6)×100=60%.
Next, the arrangement probability estimation unit for
29
each process 123 determines whether or not the calculation of
the arrangement probability in all the processes is completed
for each component code at step S1140. Then, when it is
determined that the calculation is not completed (No at step
S1140, the arrangement probability estimation unit for each
process 123 returns the process to the step S1120. At the step
S1120, the arrangement probability estimation unit for each
process 123 calculates the total number of cases (4 cases) of
the manufacturing numbers (X010, X013, X014, and X018) which
arrange the component (B001) in or after the next process (D2),
after which the process shifts to the step S1130.
At the step S1130, the arrangement probability
estimation unit for each process 123 calculates the arrangement
probability of the component (B001) in or after the process
D2. The arrangement probability of the component in or after
the process D2 becomes 4/(4+4)×100=50%.
Accordingly, the arrangement probability estimation
unit for each process 123 repeatedly executes the processes
of the steps S1120 to S1140 until the calculation of the
arrangement probability in all the processes is completed for
each product code and each component code, and calculates the
component arrangement probability for each product code, each
component code, and each process code.
Further, at the step S1140, when it is determined that
the calculation of the arrangement probability of all the
30
processes is completed for each product code and each component
code (Yes at the step S1140), the arrangement probability
estimation unit for each process 123 generates the arrangement
probability information for each process 115 at step S1150.
Specifically, the arrangement probability estimation unit for
each process 123 generates the arrangement probability
information for each process 115 in which the specified product
code, component code, and process code are associated with the
calculated arrangement probability. Further, when the
arrangement probability estimation unit for each process 123
generates the associated information, the present flow is
terminated, after which the process shifts to step S120 in FIG.
11.
AT the step S120, the number estimation unit when using
the component 124 estimates the number when using the component.
Specifically, the number estimation unit when using the
component 124 specifies a record, in which a target process
inputted as a narrowing-down condition of a target product in
a target period is scheduled to executed, from the production
plan information 201. Further, the number estimation unit
when using the component 124 executes the following process
for each specified record.
Next, the number estimation unit when using the component
124 specifies the product code (for example, A01) associated
with the specified record (for example, record 201g). Further,
31
the number estimation unit when using the component 124
specifies the component code (for example, B001) associated
with the specified product code using the component use record
information 111. Further, the number estimation unit when
using the component 124 executes the following process for each
specified component code.
Further, by using the component use record information
111, the number estimation unit when using the component 124
calculates the number when using the components (60 pieces/
6 cases=10 pieces) by diving the total number of uses
(10+10+10+10+15+5=60 pieces) associated with the specified
component code by the total number of cases (6 cases) of the
corresponding manufacturing numbers.
The number estimation unit when using the component 124
calculates the number when using a components for each product
code and each component code by repeatedly executing the
process for each product code and each component code.
Further, when the number when using the components is
calculated for each product code and each component code, the
number information when using the components which is
associated with those items is generated.
FIG. 15 is a diagram illustrating an example of the number
information when using a component 500. As illustrated in the
drawing, the number information when using the component 500
is information which is associated with the number when using
32
a component 500c for each product code 500a and each component
code 500b.
When generating the number information when using the
component 500, the number estimation unit when using the
component 124 shifts the process to step S130 in FIG. 11.
At the step S130, the prediction unit for the number of
uses for each product 125 predicts the number of uses of the
component, and the like for each product.
FIG. 16 is a flowchart illustrating details of a process
of predicting the number of uses of the component for each
product. When the process is started, the prediction unit for
the number of uses for each product 125 determines whether or
not the component arrangement information 113 of a component
related to a target product exists at step S1300. Specifically,
the prediction unit for the number of uses for each product
125 specifies a record, in which a target process in a target
period, the target process and period being inputted as a
narrowing-down condition of the target product, is scheduled
to be executed, from the production plan information 201.
Further, the prediction unit for the number of uses for each
product 125 executes the following process for each specified
record.
Next, the prediction unit for the number of uses for each
product 125 specifies the manufacturing number (for example,
Y010) and the product code (for example, A01) which are
33
associated with the specified record. Further, the prediction
unit for the number of uses for each product 125 executes the
following process for each specified manufacturing number and
each product code.
The prediction unit for the number of uses for each
product 125 specifies a record of the arrangement probability
information for each process 115 which is associated with the
specified product code (A01). Further, the prediction unit
for the number of uses for each product 125 specifies the
component code (for example, B001) from the specified record.
Additionally, the prediction unit for the number of uses for
each product 125 executes the following process for each
specified component code.
The prediction unit for the number of uses for each
product 125 determines whether or not the component arrangement
information 113 includes a record in which the specified
manufacturing number (Y010) and the specified component code
(B001) are associated with each other. Then, when it is
determined that the record is included therein (Yes at the step
S1300), the prediction unit for the number of uses for each
product 125 shifts the process to step S1310. On the other
hand, when it is determined that the record is not included
therein (No at the step S1300), the prediction unit for the
number of uses for each product 125 shifts the process to step
S1350.
34
In this example, since the record in which the
manufacturing number Y010 and the component code B001 are
associated with each other exists in the component arrangement
information 113, the prediction unit for the number of uses
for each product 125 shifts the process to the step S1310.
Next, the prediction unit for the number of uses for each
product 125 specifies the number of component arrangements at
the step S1310. Specifically, the prediction unit for the
number of uses for each product 125 specifies the number of
component arrangements (10 pieces) from the corresponding
record of the component arrangement information 113, and shifts
the process to step S1320.
Next, the prediction unit for the number of uses for each
product 125 specifies process progress at the step S1320.
Specifically, the prediction unit for the number of uses for
each product 125 specifies a record of the production plan
information 201 in which the specified manufacturing number
(Y010) and the specified product code (A01) are associated with
each other. Further, the prediction unit for the number of
uses for each product 125 specifies a process code (M) of a
record in which a completion record of an immediately preceding
process (D3) becomes “completion” and “incompletion” is
associated with the completion record as the process progress.
Further, when specifying the process progress, the prediction
unit for the number of uses for each product 125 shifts the
35
process to step S1330.
Next, the prediction unit for the number of uses for each
product 125 specifies a component use date at the step S1330.
Specifically, the prediction unit for the number of uses for
each product 125 specifies a record in which the process code
“M” indicating the manufacturing process is associated with,
among the records of the production plan information 201 in
which the specified manufacturing number (Y010) and the
specified product code (A01) are associated with each other.
Additionally, the prediction unit for the number of uses for
each product 125 specifies a process start date (June 25) of
the specified record as a use date of the component, and shifts
the process to step S1340.
Next, the prediction unit for the number of uses for each
product 125 determines whether or not prediction of the number
of uses for all the components of the target product is
completed at the step S1340. Then, when it is determined that
the prediction thereof is not completed (No at the step S1340),
the prediction unit for the number of uses for each product
125 returns the process to the step S1300. On the other hand,
when it is determined that the prediction thereof is completed
(Yes at the step S1340), the prediction unit for the number
of uses for each product 125 shifts the process to step S1370.
Here, a case, in which it is determined that the
prediction unit for the number of uses for each product 125
36
does not complete the associated prediction of the number of
uses (No at the step S1340), will be described.
At the step S1300 performed via the step S1340, the
prediction unit for the number of uses for each product 125
determines whether or not the component arrangement
information 113 with respect to a component related to an
unprocessed target product exists at the step S1300.
Specifically, the prediction unit for the number of uses for
each product 125 specifies the manufacturing number (for
example, Y011) and the product code (for example, A01) related
to the unprocessed target product from the production plan
information 201. Further, the prediction unit for the number
of uses for each product 125 executes the following process
for each specified manufacturing number and specified product
code.
The prediction unit for the number of uses for each
product 125 specifies a record of the arrangement probability
information for each process 115 with which the specified
product code (A01) is associated. Additionally, the
prediction unit for the number of uses for each product 125
specifies the component code (for example, B001) from the
specified record. Further, the prediction unit for the number
of uses for each product 125 executes the following process
for each specified component code.
The prediction unit for the number of uses for each
37
product 125 determines whether or not the component arrangement
information 113 includes a record in which the specified
manufacturing number (Y011) and the specified component code
(B001) are associated with each other. In this example, since
the record associated with the manufacturing number Y011 and
the component code B001 does not exist in the component
arrangement information 113, the prediction unit for the number
of uses for each product 125 shifts the process to the step
S1350.
Next, the prediction unit for the number of uses for each
product 125 specifies the process progress at the step S1350.
Specifically, the prediction unit for the number of uses for
each product 125 specifies the record 201g of the production
plan information 201 in which the specified manufacturing
number (Y011) and the specified product code (A01) are
associated with each other. Additionally, the prediction unit
for the number of uses for each product 125 specifies a process
code (D2) of a record in which a completion record of an
immediately preceding process (D1) becomes “completion”, and
“incompletion” is associated with the completion record as the
process progress. Further, when specifying the process
progress, the prediction unit for the number of uses for each
product 125 shifts the process to step S1360.
Next, the prediction unit for the number of uses for each
product 125 calculates the predicted number of uses of the
38
component based upon the arrangement probability for each
process at the step S1360. Specifically, the prediction unit
for the number of uses for each product 125 specifies a record
of the arrangement probability information for each process
115 in which the specified product code (Y011), the specified
component code (B001), and the specified process code (D2) are
associated with each other. Further, the prediction unit for
the number of uses for each product 125 specifies the
corresponding arrangement probability (50%) from the
specified record.
Further, the prediction unit for the number of uses for
each product 125 specifies the number (10 pieces) during the
use of the number information when using the component in which
the specified product code (Y011) and the specified component
code (B001) are associated with each other. Then, the
prediction unit for the number of uses for each product 125
calculates the predicted number of uses of the components (5
pieces) by multiplying the arrangement probability by the
number during the use. Further, when calculating the
predicted number of uses of the components, the prediction unit
for the number of uses for each product 125 shifts the process
to the step S1330.
Next, the prediction unit for the number of uses for each
product 125 specifies a component use date at the step S1330.
Specifically, the prediction unit for the number of uses for
39
each product 125 specifies a record in which the process code
“M” indicating the manufacturing process is associated with
among the records of the production plan information 201 in
which the specified manufacturing number (Y011) and the
specified product code (A01) are associated with each other.
Further, the prediction unit for the number of uses for each
product 125 specifies a process start date (June 30) of the
specified record as the component use date, and shifts the
process to the step S1340.
Next, the prediction unit for the number of uses for each
product 125 determines whether or not the prediction of the
number of uses for all the components of the target product
is completed at the step S1340. Here, it is determined that
the prediction unit for the number of uses for each product
125 completes the association prediction of the number of uses
thereof (Yes at the step S1340), and a case in which the process
shifts to the step S1370 will be described.
At the step S1370, the prediction unit for the number
of uses for each product 125 generates the prediction
information on the number of uses for each product 116.
Specifically, the prediction unit for the number of uses for
each product 125 generates the prediction information on the
number of uses for each product 116 in which the specified or
calculated manufacturing number, the corresponding product
code and component code, the process progress, the arrangement
40
existence or nonexistence, the use probability, the number
during the use, the number of uses, and the use date are
associated with each other. Further, when the prediction unit
for the number of uses for each product 125 generates the
associated information, the present flow is terminated, and
shifts the process to step S140 in FIG. 11.
At the step 140, the component order information
generation unit 126 generates the component order information
117.
FIG. 17 is a flowchart illustrating details of a process
of generating the component order information 117. When the
associated process is started, the component order information
generation unit 126 specifies the predicted number of uses of
the component at step S1400). Specifically, the component
order information generation unit 126 specifies any one of the
records of the prediction information on the number of uses
for each product 116 in which “nonexistence” is associated in
the arrangement existence or nonexistence. Further, the
component order information generation unit 126 specifies the
manufacturing number (for example, Y011), the product code
(A01), and the component code (B001) of the specified record.
Additionally, the component order information generation unit
126 specifies the number of uses of the associated records (for
example, 5 pieces) as the predicted number of uses of the
components. Further, when specifying the predicted number of
41
uses of the components, the component order information
generation unit 126 shifts the process to step S1410.
Next, the component order information generation unit
126 calculates the number of orders corresponding to a lot size
and an order amount at the step S1410. Specifically, the
component order information generation unit 126 specifies a
record of the order contract information 114 which is
associated with the component code (B001) of the specified
record. Further, the component order information generation
unit 126 specifies the lot size (5 pieces) associated with the
specified record. Additionally, the component order
information generation unit 126 calculates the number of orders
(5 pieces) corresponding to the specified predicted number of
uses of the components (5 pieces) and the lot size (5 pieces).
Further, the component order information generation unit
126 specifies a unit price (10k¥) of the order contract
information 114 which is associated with the specified
component code (B001). Additionally, the component order
information generation unit 126 calculates the order amount
(50k¥) by multiplying the calculated number of orders (5
pieces) by the unit price (10k¥). Further, when calculating
the order amount, the component order information generation
unit 126 shifts the process to step S1420.
Next, the component order information generation unit
126 calculates an order date and a delivery deadline of the
42
component at the step S1420. Specifically, the component
order information generation unit 126 specifies the use date
(June 30) of a record which is associated with the specified
manufacturing number (Y011) and the specified component code
(B001) from the prediction information on the number of uses
for each product 116.
Further, the component order information generation unit
126 specifies the record of the order contract information 114
which is associated with the specified component code (B001).
Further, the component order information generation unit 126
specifies a procurement lead time (30 days) which is associated
with the specified record. Additionally, the component order
information generation unit 126 calculates the order date (for
example, May 30) by counting backward the number of days in
which a reserved day (for example, one day) is added to the
specified procurement lead time (30 days) from the use date
(June 3 0 ).
Further, the component order information generation unit
126 specifies the use date (June 30) of the record which is
associated with the specified manufacturing number (Y011) and
the specified component code (B001) from the prediction
information on the number of uses for each product 116. Further,
the component order information generation unit 126 calculates
the day before the specified use date as the delivery deadline
of the component, and shifts the process to step S1430.
43
Next, the component order information generation unit
126 generates the component order information 117 in which the
specified or calculated component code, the order date, the
number of orders, the order amount, the delivery deadline, and
an arbitrary order code are associated with each other at the
step S1430.
Next, the component order information generation unit
126 determines whether or not the component order information
117 is generated for all the target components at step S1440.
Specifically, the component order information generation unit
126 determines whether or not the component order information
117 is generated for the components related to all the records
of the prediction information on the number of uses for each
product 116. When it is determined that there exists an
unprocessed component (No at the step S1440), the component
order information generation unit 126 shifts the process to
the step S1400. On the other hand, when it is determined that
the generation of the component order information 117 is
generated for the components related to all the records (Yes
at the step S1440), the component order information generation
unit 126 terminates the present flow and shifts the process
to step S150 in FIG. 11.
At the step S150, the stock transition prediction unit
127 predicts the stock transition of the component.
44
Specifically, the stock transition prediction unit 127
specifies the component code, the number of uses, and the use
date which are associated with each record of the prediction
information on the number of uses for each product 116, and
specifies the number of uses and the use date as the number
of delivery and the delivery date respectively.
Further, the stock transition prediction unit 127
specifies the component code, the number of orders, and the
delivery deadline which are associated with each record of the
component order information 117, and specifies the number of
orders and the delivery deadline as the number of warehousing
and the warehousing date respectively.
Further, the stock transition prediction unit 127
replaces the sequence according to the specified warehousing
date and the specified delivery date, and calculates the number
of stocks based upon a difference between the number of
warehousing and the number of delivery.
Further, the stock transition prediction unit 127
generates the stock transition information 118 in which the
specified component code, the warehousing and delivery
sections, the number of warehousing and delivery, the date of
warehousing and delivery, and the number of stocks are
associated with each other. Further, the record 118f of the
stock transition information 118 illustrated in FIG. 9
indicates that 10 pieces of the components of the component
45
code B001 are scheduled to be put into a warehouse on June 24,
and the number of stocks becomes 10 pieces. Further, the record
118g indicates that since 10 pieces of the components of the
component code B001 are scheduled to be delivered on June 25,
the number of stocks thereof becomes zero. Additionally, when
generating the stock transition information 118, the stock
transition prediction unit 127 shifts the process to step S160.
At the step S160, the output process unit 122 generates
screen information which displays predetermined output
information such as the component order information 117, the
stock transition information 118, and the like, and outputs
the generated screen information to the display device 302.
Specifically, the output process unit 122 generates graph
display information which indicates the stock transition of
the component using the stock transition information 118.
Further, the output process unit 122 generates display
information which indicates the predicted number of uses of
the component for each product using the prediction information
on the number of uses for each product 116. Further, the output
process unit 122 generates graph display information which
indicates the component arrangement probability for each
process by using the arrangement probability information for
each process 115. Additionally, the output process unit 122
outputs the generated display information to the display device
302.
46
FIG. 18 illustrates an example of a display screen 600
on which output information is displayed. As illustrated in
the drawing, the display screen 600 is provided with a display
region 601 which displays component stock transition; a display
region 610 which displays the predicted number of uses of the
component for each product; and a display region 620 which
displays the component arrangement probability for each
process.
A graph display information 602 which indicates
component stock transition, input fields 603 and 603 which
designate a component code and a display period to be displayed
in the graph display information, a display button 605 which
receives a display instruction, and an order information
confirmation button 606 which receives a display instruction
of the component order information 117 are displayed in the
display region 601 which displays the component stock
transition. Further, the graph display information 602 is
graph information in which the number of stocks of the component
is displayed in time series, and a vertical axis indicates the
number of stocks, and a horizontal axis indicates the date.
For example, when a user inputs the predetermined
component code and the display period thereof to the input
fields 603 and 604 via the input device 301 and presses down
the display button 605, the output process unit 122 extracts
information corresponding to the component code and the display
47
period which receives the input from the stock transition
information 118, generates and displays the generated graph
display information 602.
Further, when the user presses down the order information
confirmation button 606 via the input device 301, the output
process unit 122 extracts and displays the record of the
component order information 117 which is associated with the
component code inputted in a component code input field.
Display information 611 of the prediction information
on the number of uses for each product 116 with respect to a
component inputted to the component code input field 603, and
a re-execution button 612 which changes the number of uses of
the displayed prediction information on the number of uses for
each product 116 and receives a generation instruction of the
prediction information on the number of uses for each product
116 again are displayed in the display region 610 which displays
the predicted number of uses of the component for each product.
For example, when the user changes the number of uses
from the display information 611 of the prediction information
on the number of uses for each product 116 via the input device
301 and presses down the re-execution button 612, the
corresponding functional unit of the calculation unit 120
executes the process in or after the above-described step S140
again based upon the changed number of uses, and generates the
component order information 117 and the stock transition
48
information 118 based upon the changed number of uses. Further,
the output process unit 122 generates screen information for
being displayed on the corresponding display region by using
the newly generated information. According to the
above-mentioned process, the user can review the contents of
the component order information 117.
Graph display information 621 which indicates the
arrangement probability for each process in which the
manufacturing number, the product code, and the component code
of the record which is selected by the prediction information
on the number of uses for each product 116 are associated with
each other is displayed in the display region 620 which displays
the component arrangement probability for each process. In
the graph display information, a vertical axis indicates the
arrangement probability, and a horizontal axis indicates the
process.
Further, a display form of the output information is not
particularly limited, and various display forms are possible.
For example, the output process unit 122 only displays the input
fields 603 and 604 of the component code and the display period
and the display button 605 which receives the display
instruction on the display screen 600, and the graph display
information 602 which indicates the stock transition of the
corresponding component code and display period when receiving
the component code and the display period from the user, and
49
the display information 611 of the prediction information on
the number of uses for each product 116. Additionally, the
output process unit 122 displays the component order
information 117 corresponding to the component code and the
display period received from the user on a pop-up screen.
Additionally, the output process unit 122 displays, for
example, an arrangement probability display button which
receives the display instruction of the arrangement
probability of the target component in the display region 610
which displays the prediction of the number of uses of the
component for each product, and when the button is pressed down,
the graph display information 621 which indicates the
arrangement probability for each process may be generated and
displayed.
Further, the embodiment is described on the assumption
that the component of the component code used in the past will
be arranged (ordered) for the same component even in the further,
and however, for example, depending on the supplier, a
component version may be changed from a certain time, and
another option may be generated in the component to be used
depending on a design specification. In the former case, for
example, when generating the component order information 117
at the step S140, the component order information 117 in which
the component version is switched based upon the delivery
deadline or the order date may be generated.
50
Further, in the latter case, for example, when predicting
the number of uses of the component for each product at the
step S130, the arrangement probability may be calculated for
each component having the selection possibility from the record
of the past design specification, and the like, and the
respective number of uses may be predicted.
As described above, according to the component order
system of the embodiment, it is possible to perform the
prediction of the number of uses of the component corresponding
to the process progress such as the design, and the like with
high accuracy even in the individual order reception design
product in which the type and quantity of component required
for the product cannot be confirmed and the component is
arranged while the product design is performed step by step,
thereby making it possible to suppress an increase in stock
due to the component order and delivery more than necessary.
Further, in the component order system, the output
information is displayed, thereby allowing the user to confirm
and determine the contents of the component order information
117 while confirming the stock transition, the arrangement
probability for each process, and the like. Additionally, the
component order system receives a variation in the number of
uses from the user on the screen displaying the prediction of
the number of uses of the component for each product, and can
display information on the component order information 117 and
51
the stock transition after the change. Accordingly, it is
possible to dramatically improve the usability of the user.
[Second Embodiment]
Next, the second embodiment of the present invention will
be described. The component order system according to the
embodiment can evaluate the number of stocks and order amount,
and the like when the lot size, the unit price, and the like
of the ordered component are changed, thereby making it
possible to support the review of a valid order contract.
Further, since a basic configuration of the component order
system according to the second embodiment is the same as that
of the first embodiment, different configurations and
processes will be mainly described, and descriptions of common
configurations and processes will be appropriately omitted.
FIG. 19 is a diagram illustrating an example of a
schematic configuration of the component order system
according to the second embodiment. The component order
device 100 includes an order contract pattern generation unit
128 in addition to the functional units described in the first
embodiment.
The order contract pattern generation unit 128 is a
functional unit which generates an order contract pattern.
Specifically, the order contract pattern generation unit 128
is the functional unit which generates order contract pattern
information 119 in a component order information generation
52
process which will be described later.
FIG. 20 is a diagram illustrating an example of the order
contract pattern information 119 generated by the order
contract pattern generation unit 128. The order contract
pattern information 119 is information which indicates
contents of the order contract for each order contract pattern
in which a predetermined item of the order contract information
114 is changed, and is information corresponding to the order
contract information 114 of the first embodiment (FIG. 5 ) .
Specifically, the order contract pattern information 119
includes a record in which an order contract pattern 119a, a
component code 119b, a procurement lead time 119c, a lot size
119d, and a unit price 119e are associated with each other.
The order contract pattern 119a is identification
information which manages and identifies the order contract
pattern. The component code 119b is information which
identifies a component used for a product to be manufactured,
and is common to the component code 111c of the component use
record information 111. The procurement lead time 119c is
information which indicates a lead time until a procured
component is put into a warehouse. The lot size 119d is
information which indicates a minimum unit when a component
is ordered. The unit price 119e is information which indicates
an order unit price of a component. For example, the record
119f indicates that the order contract pattern, in which the
53
procurement lead time is 30 days, the lot size is 8 pieces,
and the unit price is 8K¥ with respect to the component code
B001, is P02.
FIG. 21 is a diagram illustrating an example of a
component order information generation process according to
the embodiment. The associated process is started when the
input reception unit 121 receives an execution instruction from
a user. When receiving the execution instruction of the
component order information generation process, the input
reception unit 121 generates input screen information for
receiving a narrowing-down condition of a product which becomes
a generation target of the component order information 117 and
a condition of the order contract pattern via the output process
unit 122, and displays the generated input screen information
on the display device 302.
FIG. 22 is a diagram illustrating an input screen example
700 which receives a narrowing-down condition of a target
product and a condition of an order contract pattern. An order
contract pattern condition field 710 is an input field which
inputs a variation ratio of predetermined items such as a
generation condition of the order contract pattern information
119, that is, the procurement lead time 114b, the lot size 114c,
the unit price 114d, and the like which are registered in the
order contract information 114.
Specifically, a record in which the predetermined items
54
(for example, the procurement lead time, the lot size, and the
unit price) included in the order contract information 114 is
associated with a check box which receives selection is
displayed in the order contract pattern condition field 710.
Further, when an addition button 711 is pressed down, a record
for receiving the input of the variation ratio with respect
to each item from the user is generated in the order contract
pattern condition field 710. When the variation ratio desired
by the user is inputted in each item and the pressing of the
execution button 406 is received, the input reception unit 121
starts the component order information generation process
using the inputted condition. Further, since the processes
of the steps S100 to S130 are the same as those of the first
embodiment, the descriptions thereof will be omitted.
At step S135, the order contract pattern generation unit
128 generates the order contract pattern information 119.
Specifically, the order contract pattern generation unit 128
specifies the component code (for example, B001) for each
record included in the prediction information on the number
of uses for each product 116 generated at the step S130.
Further, the order contract pattern generation unit 128
extracts a record of the order contract information 114 which
is associated with the specified component code (B001).
Additionally, the order contract pattern generation unit 128
generates the order contract pattern information 119 by
55
multiplying the variation ratio of the predetermined items (the
lot size and the unit price) inputted in the order contract
pattern condition field 710 by a value of the corresponding
item of the extracted record.
Further, in the processes of the steps S140 and S150,
the component order information 117 and the stock transition
information 118 are generated for each order contract pattern
using the order contract pattern information 119 instead of
the order contract information 114. Specifically, the
component order information generation unit 126 and the stock
transition prediction unit 127 generate the component order
information 117 and the stock transition information 118 for
each order contract pattern using the procurement lead time
119b, the lot size 119c, and the unit price 119d respectively
associated with the respective order contract patterns (for
example, P01, P02, and P03) 119a of the order contract pattern
information 119.
FIG. 23 is a diagram illustrating an example of the
component order information 117 generated using the order
contract pattern information 119. As illustrated in the
drawing, the component order information 117 is associated with
the number of orders 117d, the order price 117e, and the like,
calculated for each order contract pattern (P01, P02, and P03)
117x.
FIG. 24 is a diagram illustrating an example of the stock
56
transition information 118 generated using the order contract
pattern information 119. As illustrated in the drawing, the
stock transition information 118 is associated with the number
of warehousing or delivery 118c, the number of stocks 118e,
and the like calculated for each order contract pattern (P01,
P02, and P03) 118x.
Further, at the step S160, the output process unit 122
generates screen information which displays information
including a total amount of order and an average amount of stock
for each order contract pattern in addition to predetermined
output information such as the component order information 117,
the stock transition information 118, and the like, and outputs
the generated screen information to the display device 302.
FIG. 25 illustrates a display screen example 800 which
displays output information. As illustrated in the drawing,
table information 801, in which the lot size, the unit price,
the total amount of order, and the average amount of stock for
each order contract pattern are associated with the graph
display information 602 indicating the stock transition of the
component, is displayed in the display region 601 which
displays the component stock transition.
When generating the table information 801, the output
process unit 122 specifies a record which is associated with
the component code (B001) inputted in the input field 603 of
the component code from the order contract pattern information
57
119. Further, the output process unit 122 extracts the values
of the predetermined items (the lot size and the unit price)
inputted in the order contract pattern condition field 710 from
the specified record. Additionally, the output process unit
122 calculates the total number of orders of the component code
(B001) (for example, 100+50+100=250 pieces in the order
contract pattern P01) for each order contract pattern using
the component order information 117. Further, the output
process unit 122 calculates the average amount of stocks per
day by multiplying the total number of orders by a predetermined
coefficient for each order contract pattern. Further, the
output process unit 122 generates the table information 801
in which the extracted predetermined items, the total number
of orders, and the average amount of stock are associated with
each other, and displays the generated table information 801
in a predetermined display region.
When a predetermined record is selected by a selection
button of the table information 801 and a stock transition
display button 802 is pressed down, the output process unit
122 specifies a record of the stock transition information 118
which is associated with the order contract pattern of the
selected record. Further, the output process unit 122
generates and displays the graph display information 601 which
indicates the stock transition of the component using the
specified record.
58
Further, the table information 801 including the total
amount of order, and the like may be displayed, for example,
in the display region 610 which displays the prediction of the
number of uses of the component for each product or the display
region 620 which displays the component arrangement
probability for each process.
As described above, according to the component order
system of the embodiments, it is possible to evaluate the
procurement cost and stock transition when the order contract
such as the procurement lead time, the lot size, and the unit
price of the component is changed. As a result, the user can
review the valid order contract.
Further, the present invention is not limited to the
embodiments described above, but includes various
modifications. For example, the above-mentioned embodiments
are described in detail in order to describe the present
invention in an easy-to-understand manner, and are not
necessarily limited to those including all of the
configurations described herein. Further, a part of the
configuration of one embodiment can be replaced with a
configuration of another embodiment, and the configuration of
another embodiment can be added to the configuration of one
embodiment. Further, it is possible to add, delete, and
replace another configuration with respect to a part of the
configuration of each embodiment.
59
Further, in the above descriptions, the control line and
the information line indicate what is considered to be
necessary for the descriptions, and all the control lines and
information lines are not necessarily shown on the products.
In fact, it can be considered that almost all the configurations
are connected to each other.

WE CLAIM:
1. A component order system, comprising:
a component order device configured to generate
component order information; and
a production plan system configured to transmit
production plan information which manages a production plan
of a product to the component order device, wherein
the component order device comprises an arrangement
probability estimation unit for each process configured to
calculate arrangement probability of a component for each
manufacturing process in a product manufactured in the past,
a number estimation unit when using a component
configured to calculate the number when using the component
in the product manufactured in the past,
a prediction unit for the number of uses for each product
configured to define the arrangement probability of the
component corresponding to process progress of the product to
be specified from the production plan information as use
probability of the component, and configured to predict the
number of uses of the component based on the use probability
and the number when using the component, and
a component order information generation unit configured
to calculate the number of orders of the component based on
the number of uses of the component and a lot size which is
a minimum order unit of the component, and configured to
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generate component order information including the calculated
number of orders.
2. The component order system according to claim 1,
wherein
the prediction unit for the number of uses for each
product specifies a manufacturing process start date of the
product to be specified using the production plan information
as a use date of the component, and
the component order information generation unit
calculates a delivery deadline of the component based upon the
specified use date of the component,
calculates an order date of the component based upon a
procurement lead time of the component,
calculates an order amount of the component based upon
the number of orders of the component, the lot size thereof,
and a unit price thereof, and
generates the component order information which the
delivery deadline, the order date, the order amount, and the
number of orders are associated with.
3. The component order system according to claim 2,
further comprising:
a stock transition prediction unit configured to
specify the number of orders and the delivery deadline
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of the component order information as the number of warehousing
of the component and a warehousing date thereof, respectively,
specify the number of uses and the use date of the
component as the number of delivery of the component and a
delivery date thereof, respectively, and
calculate transition of the number of stocks of the
component based on a difference between the number of
warehousing of the component and the number of delivery
thereof.
4. The component order system according to claim 3,
further comprising:
an output process unit configured to generate display
screen information of the component order information.
5. The component order system according to claim 4,
wherein
the output process unit generates display screen
information in which the number of stocks of the component is
graphed in time series.
6. The component order system according to claim 4,
wherein
the output process unit generates display screen
information of prediction information on the number of uses
63
for each product which at least the product and the component,
the process progress, the use probability, and the number of
uses are associated with.
7. The component order system according to claim 6,
further comprising:
an input reception unit configured to receive a change
with respect to the number of uses of the displayed prediction
information on the number of uses for each product, wherein
when the input reception unit receives the change of the
number of uses, the component order information generation unit
regenerates the component order information using the inputted
number of uses of the component after the change.
8. The component order system according to claim 7,
wherein
the stock transition prediction unit recalculates the
number of stocks using the inputted number of uses of the
component after the change and the regenerated component order
information.
9. The component order system according to claim 2,
wherein
the component order information generation unit
generates component order information including the order date,
64
the number of orders, the order amount, and the delivery
deadline which are obtained for each pattern in which any one
of the procurement lead time, the lot size, and the unit price
is varied.
10. The component order system according to claim 9,
further comprising:
an output process unit configured to calculate an total
amount of the order of the component and an average amount of
stock per day using the component order information including
the items which are obtained for each pattern, and configured
to generate display screen information of the total amount of
order and the average amount of stock.
11. A component order device, comprising:
an arrangement probability estimation unit for each
process configured to calculate arrangement probability of a
component for each manufacturing process in a product
manufactured in the past;
a number estimation unit when using a component
configured to calculate the number when using the component
in the product manufactured in the past;
a prediction unit for the number of uses for each product
configured to define the arrangement probability of the
component corresponding to process progress of the product as
65
use probability of the component, and configured to predict
the number of uses of the component based upon the use
probability and the number when using the component; and
a component order information generation unit configured
to calculate the number of orders of the component based upon
the number of uses of the component and a lot size which is
a minimum order unit of the component, and configured to
generate component order information including the calculated
number of orders.
12. The component order device according to claim 11,
wherein
the component order information generation unit
calculates a delivery deadline of the component based upon a
use date of the component which is specified by the prediction
unit for the number of uses for each product,
calculates an order date of the component based upon a
procurement lead time of the component,
calculates an order amount of the component based upon
the number of orders of the component, the lot size thereof,
and a unit price thereof, and
generates the component order information which the
delivery deadline, the order date, the order amount, and the
number of orders are associated with.