1. A production plan planning method for storing, by a computer comprising a processor and a storage, production schedule information on at least one first component constituting a product and at least one second component constituting the at least one first component, in a productio5 n schedule information storage part of the storage, receiving an order for the product, and generating a production process for the product, the production plan planning method comprising: a first step of receiving, by the computer, the order including 10 production time information on the product in a received order condition as received order information; a second step of searching, by the computer, the production schedule information storage part for production schedule information on the product stored in the received order information; 15 a third step of allocating, by the computer, production schedule information on each process for the at least one first component to the retrieved production schedule information; and a fourth step of controlling, by the computer, the allocated production schedule information on the each process to take over the production time 20 information, the third step comprising allocating production schedule information satisfying the production time information included in the received order condition of the received order information to the each process, the fourth step comprising controlling the respective allocated 25 processes to sequentially take over production time information on a first process of the product.

2. The production plan planning method according to claim 1, wherein the third step comprises searching stock information storage part 39 for storing stock information on the at least one first component for stock information satisfying the production time information included in the received order condition, and, when the stock information satisfying the production time information included in the received order condition exists, allocating the stock information to the process in priority to the 5 production schedule information.

3. The production plan planning method according to claim 1, wherein the third step comprises newly generating, when the production 10 schedule information satisfying the production time information included in the received order condition of the received order information is not allocable to the process, production schedule information to be allocated to the process. 15 4. The production plan planning method according to claim 2, wherein the third step comprises newly generating, when the production schedule information and the stock information satisfying the production time information included in the received order condition of the received order information are not allocable to the process, production schedule 20 information to be allocated to the process.

5. The production plan planning method according to claim 3, further comprising outputting, when the production schedule information satisfying the production time information included in the received order condition of 25 the received order information is not allocable to the process, a notification that the allocation is unavailable.

6. The production plan planning method according to claim 2, wherein the third step comprises allocating, when a plurality of pieces of 40 stock information satisfying the production time information included in the received order condition exist, stock information oldest in the production time information to the process.

7. The production plan planning method according to claim 5 1, further comprising a fifth step of outputting, by the computer, screen information for displaying the received order information, which has been received, and the allocated production schedule information as a time series. 10 8. A production plan planning apparatus, comprising a processor and a storage, for storing production schedule information on at least one first component constituting a product and at least one second component constituting the at least one first component, in a production schedule information storage part of the storage, receiving an order for the product, 15 and generating a production process for the product, the production plan planning apparatus further comprising: a received order information acquisition part for receiving the order including production time information on the product in a received order condition as received order information; and 20 an allocation processing part for searching the production schedule information storage part for production schedule information on the product stored in the received order information, allocating production schedule information on each process for the at least one first component to the retrieved production schedule information, and controlling the allocated 25 production schedule information on the each process to take over the production time information, the allocation processing part being configured to allocate production schedule information satisfying the production time information included in the received order condition of the received order information to the each 41 process, and control the respective allocated processes to sequentially take over production time information on a first process of the product.

9. A non-transitory computer-readable storage medium having stored thereon a program for controlling a computer comprising a processor and 5 a storage to store production schedule information on at least one first component constituting a product and at least one second component constituting the at least one first component, in a production schedule information storage part of the storage, receive an order for the product, and 10 generate a production process for the product, the program further controlling the computer to execute: a first procedure of receiving the order including production time information on the product in a received order condition as received order information; 15 a second procedure of searching the production schedule information storage part for production schedule information on the product stored in the received order information; a third procedure of allocating production schedule information on each process for the at least one first component to the retrieved production 20 schedule information; and a fourth procedure of controlling the allocated production schedule information on the each process to take over the production time information, the third procedure comprising allocating production schedule 25 information satisfying the production time information included in the received order condition of the received order information to the each process, the fourth procedure comprising controlling the respective allocated processes to sequentially take over production time information on a first 42 process of the product.

10. The program according to claim 9, wherein the third procedure comprises searching stock information storage part for storing stock information on the at least one first component for 5 stock information satisfying the production time information included in the received order condition, and, when the stock information satisfying the production time information included in the received order condition exists, allocating the stock information to the process in priority to the production schedule 10 information.

11. The program according to claim 9, wherein the third procedure comprises newly generating, when the production schedule information satisfying the production time information included in the received order 15 condition of the received order information is not allocable to the process, production schedule information to be allocated to the process.

12. The program according to claim 10, wherein the third procedure comprises newly generating, when the production schedule information and 20 the stock information satisfying the production time information included in the received order condition of the received order information are not allocable to the process, production schedule information to be allocated to the process. 25 13. The program according to claim 11, wherein the program controls the computer to execute outputting, when the production schedule information satisfying the production time information included in the received order condition of the received order information is not allocable to the process, a notification that the allocation is unavailable. 43

14. The program according to claim 10, wherein the third procedure comprises allocating, when a plurality of pieces of stock information satisfying the production time information included in the received order condition exist, stock information oldest in the production time 5 me information to the process.

15. The program according to claim 9, wherein the program further controls the computer to execute a fifth procedure of outputting screen 10 information for displaying the received order information, which has been received, and the allocated production schedule information as a time series.

PRODUCTION PROJECT PROPOSAL DETERMINATION METHOD,
PRODUCTION PROJECT PROPOSAL DEVICE AND PROGRAM
BACKGROUND OF THE INVENTION
This invention relates to a technology for managing, on a computer, 5 mputer, a
production plan for producing a product, and more particularly, to
improvement of a technology for managing a production schedule or stock
satisfying a received order condition.
In recent years, in the manufacturing industry, a production plan is
10 planned by simply allocating, when there are products in stock or products
scheduled to be produced which can be allocated to a received order, those
products in a first-in/first-out manner. However, there are an increasing
number of cases in which customer needs cannot be met by such a simple
algorithm as that of the related-art production plan planning system. In
15 order to meet the needs of customers, for example, there has been proposed,
as a production management system adapted to a case in which needs of
customers change and a sudden inquiry for order is received, a technology of
updating calculated component procurement conditions on a component
vendor side in response to a change in product order reception conditions
20 (for example, JP 2006-39869 A).
Moreover, in a production plan planning system for producing foods
as products, a valid period starting from a production completion date when
the production of the product is completed is set, and the products are
shipped or delivered within the valid period.
25
SUMMARY
However, in the related-art production plan planning system, a
production plan is planned by a deployment in only in direction, namely,
only by a backward deployment (from future to past) or a forward
3
deployment (from past to future) with respect to a production completion
date based on a product, a quantity, and a due date. Therefore, there has
been such a problem that, if a condition for a production start date is added
as production time information on a component or a product when an order
is received from a customer, it is not possible to select products 5 ts to be
delivered in consideration of the condition, and thus it is difficult to satisfy
restraint of an excess or deficiency of an allocated quantity and minimized
disposal of components at the same time.
In particular, if one product is manufactured from a plurality of
10 components (or intermediate products), respective production start dates
need to satisfy the received order condition. However, the related-art
examples have such a problem that the production start dates cannot be
acquired for all the components constituting one product.
A representative aspect of the present disclosure is as follows. A
15 production plan planning method for storing, by a computer comprising a
processor and a storage, production schedule information on at least one
first component constituting a product and at least one second component
constituting the at least one first component, in a production schedule
information storage part of the storage, receiving an order for the product,
20 and generating a production process for the product, the production plan
planning method comprising: a first step of receiving, by the computer, the
order including production time information on the product in a received
order condition as received order information; a second step of searching, by
the computer, the production schedule information storage part for
25 production schedule information on the product stored in the received order
information; a third step of allocating, by the computer, production schedule
information on each process for the at least one first component to the
retrieved production schedule information; and a fourth step of controlling,
by the computer, the allocated production schedule information on the each
4
process to take over the production time information, the third step
comprising allocating production schedule information satisfying the
production time information included in the received order condition of the
received order information to the each process, the fourth step comprising
controlling the respective allocated processes to sequentially take 5 e over
production time information on a first process of the product.
According to one embodiment this invention, even when a condition
for the production time information on a product is added when an order is
received, optimal products can be easily selected in consideration of the
10 condition, and thus the restraint of an excess or deficiency of an allocated
quantity and the minimized disposal of components and raw materials can
be satisfied at the same time.
BRIEF DESCRIPTION OF THE DRAWINGS
15 FIG. 1 is a block diagram illustrating an example of a computer
system constructed mainly of a production plan planning apparatus
according to a first embodiment of this invention.
FIG. 2 shows an example of the received order information recording
part according to a first embodiment of this invention.
20 FIG. 3 shows an example of the stock information recording part
according to the first embodiment of this invention.
FIG. 4 shows an example of the allocation information recording part
according to the first embodiment of this invention.
FIG. 5 shows an example of the component information recording
25 part according to the first embodiment of this invention.
FIG. 6 shows an example of the process information recording part
according to the first embodiment of this invention.
FIG. 7 shows an example of the production schedule information
recording part according to the first embodiment of this invention.
5
FIG. 8 shows an example of the production instruction information
recording part according to the first embodiment of this invention.
FIG. 9 is a flowchart illustrating an example of processing carried out
by the received order information acquisition part according to the first
5 embodiment of this invention.
FIG. 10 is a flowchart illustrating an example of processing carried
out by the received order condition analysis part according to the first
embodiment of this invention.
FIG. 11 is a flowchart illustrating an example of processing carried
10 out by the production schedule information acquisition part according to the
first embodiment of this invention.
FIG. 12 is a flowchart illustrating an example of processing carried
out by the allocation processing execution part according to the first
embodiment of this invention.
15 FIG. 13A is a flowchart illustrating an example of processing of the
first half carried out in the allocation processing according to the first
embodiment of this invention.
FIG. 13B is a flowchart illustrating an example of processing of the
last half carried out in the allocation processing according to the first
20 embodiment of this invention.
FIG. 14 is a screen image illustrating an example of received orders
and production schedules on the display apparatus according to the first
embodiment of this invention.
FIG. 15 is a screen image illustrating an example of the received
25 order information input screen according to the first embodiment of this
invention.
FIG. 16 is a screen image illustrating an example of a received order
information detail display screen according to the first embodiment of this
invention.
6
FIG. 17 is a screen image illustrating an example of the production
schedule information input screen according to the first embodiment of this
invention.
FIG. 18 is a screen image illustrating an example of a production
schedule information detail display screen according to the first 5 irst embodiment
of this invention.
FIG. 19 is a time chart illustrating an example of allocations of a
received order, components, and a product according to the first
embodiment of this invention.
10 FIG. 20A illustrates a first half of the processing carried out by the
allocation processing execution part according to a second embodiment of
this invention.
FIG. 20B illustrates a last half of the processing carried out by the
allocation processing execution part according to the second embodiment of
15 this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A description is now given of embodiments of this invention referring
to the accompanying drawings.
20
FIG. 1 is a block diagram illustrating an example of a configuration of
a computer system constructed mainly of a production plan planning
apparatus 1 according to a first embodiment of this invention.
The production plan planning apparatus 1 is coupled to a
25 management terminal apparatus 100 via a network 200. The management
terminal apparatus 100 includes an input apparatus and a display
apparatus, which are not shown, for receiving an input from a user and an
administrator, and inputs various requests to the production plan planning
apparatus 1.
7
The production plan planning apparatus 1 includes a processor 4 for
carrying out calculation processing, a main storage 2 for holding programs
and data, an auxiliary storage 3 including a non-volatile storage medium for
holding data and programs, an input apparatus 6 including a keyboard and
a mouse, and an output apparatus 5 including 5 a display and a printer.
The main storage 2 holds a received order information acquisition
part 21, a production schedule information acquisition part 24, a received
order condition analysis part 22, and an allocation processing execution part
25. The auxiliary storage 3 includes a received order information recording
10 part 31, a production schedule information recording part 35, a stock
information recording part 32, an allocation information recording part 36, a
production instruction information recording part 33, a component
information recording part 37, and a process information recording part 34.
Respective functional parts including the received order information
15 acquisition part 21, the production schedule information acquisition part 24,
the received order condition analysis part 22, and the allocation processing
execution part 25 are loaded from the auxiliary storage 3 into the main
storage 2 as programs.
The processor 4 operates in accordance with the programs of the
20 respective functional parts, thereby operating as the functional parts for
realizing predetermined functions. For example, the processor 4 operates in
accordance with a received order information acquisition program, thereby
functioning as the received order information acquisition part 21. The same
holds true for the other programs. Further, the processor 4 also operates as
25 a functional part of realizing a plurality of respective pieces of processing
carried out by the respective programs. The computer and the computer
system are an apparatus and a system including these functional parts.
Information such as programs and tables for realizing each of the
functions can be stored in a memory device such as the auxiliary storage 3,
8
a non-volatile semiconductor memory, a hard disk drive, and a solid state
drive (SSD), and a computer-readable non-transitory data storage medium
such as an IC card, an SD card, and a DVD.
A description is now given of an overview of the respective functional
parts. The received order information acquisition part 21 checks validity o5 f
input values from received order information (or order information) input on
the management terminal apparatus 100, and stores the information in the
received order information recording part 31. The production schedule
information acquisition part 24 checks validity of input values from
10 production schedule information input on the management terminal
apparatus 100, and records the production schedule information in the
production schedule information recording part 35. The received order
condition analysis part 22 acquires a received order condition included in
the received order information from the received order information recording
15 part 31, and converts the received order condition into predetermined
information to be handled inside the production plan planning apparatus 1.
The allocation processing execution part 25 acquires information from the
component information recording part 37, the process information recording
part 34, the received order information recording part 31, and the
20 production schedule information recording part 35, and manages the
execution of allocation processing. The allocation processing includes
allocating production schedule information on a product to received order
information, allocating processes for producing components or raw materials
starting from the production schedule information, and determining a
25 production period for each of the processes. Then, in the allocation
processing, production time information is taken over from a process of a
production start toward a production process for the end product. Finally,
in the allocation processing, a combination of processes having production
time information on the respective components and the product satisfying
9
the received order condition included in the received order information is
generated.
On this occasion, the production time information includes a date (or
a time or a date and a time) of the production start and a date (or a time or a
date and a time) of production completion, and the production start 5 date is
taken over to a following process between processes. The production
completion date represents a date when manufacturing of a product or a
component is completed. In contrast, the production start date is the oldest
production start date (or the oldest time or the oldest date and time) out of
10 the production start dates if components and materials or raw materials
constituting the product, and is taken over to the respective processes. For
example, if a product A is manufactured from a material B manufactured
from a raw material C, a date of starting processing of the raw material C is
taken over to the material B and then to the product A as the production
15 start date. A detailed description is later given of each of the functional
parts.
On the other hand, a production period of each process includes a
date (or a time or a date and a time) of production start and a date (or a time
or a date and a time) of production completion of the each process, and is
20 not taken over between processes.
In this embodiment, a description is given of an end product, a
component constituting the end product, and a raw material constituting the
component as an example, but this invention is not limited to this example
and can be applied to various products and materials in this configuration
25 relationship. In other words, such a relationship that a product, first
components constituting the product, and second components constituting
the first components is only necessary.
A description is now given of information on tables and the like stored
in the auxiliary storage 3. The received order information recording part 31
10
stores information on received orders input from the management terminal
apparatus 100. The production schedule information recording part 35
stores information on products (or components, materials, and raw
materials) to be produced input from the management terminal apparatus
100. The stock information recording part 32 stores information on 5 stocks
of raw materials, materials, intermediate products, and products.
The allocation information recording part 36 stores information on
allocation sources and allocation destinations for received orders, stocks,
production schedules, and production instructions. The production
10 instruction information recording part 33 stores production instruction
information generated by the allocation processing execution part 25. The
production instruction information is a production schedule automatically
generated by the allocation processing execution part 25, and may be treated
as production schedule information having a fixed allocation destination.
15 The component information recording part 37 stores information on
parent/child relationships between components (or products and materials).
The process information recording part 34 stores periods (lead times)
required for operations of producing components or products.
FIG. 2 shows an example of the received order information recording
20 part 31. The received order information recording part 31 includes entries
each including a received order ID 311 for storing an identifier of received
order information, an item name 312 for storing a name of a product, a
quantity 313 for storing a quantity of the ordered product, a due date 314
for storing a time limit of delivery, an unavailable allocation 315 for storing
25 an insufficient quantity of allocation subjects if sufficient allocation subjects
satisfying a received order condition are not available, a received order
condition 316 for storing the condition specified by a customer when the
order is received, a production start date and time 317 for storing a
production start date and time of the product calculated from the received
11
order condition, and a processed allocation 318 representing whether
allocation for the received order of this entry has been completed or not.
Regarding the calculation of the production start date and time 317, if the
received order condition 316 is such a condition that the production is
started within X days, the received order information acquisition part 5 21
calculates a date and time within X days from a time point of receiving the
order.
The received order ID 311 is a unique value assigned by the received
order information acquisition part 21. The unavailable allocation 315 stores
10 a quantity of allocation subjects for which allocation is not available. If the
unavailable allocation 315 is 0, the ordered quantity 313 is allocated, and if
the unavailable allocation 315 is more than 0, the unavailable allocation 315
represents a quantity of products for which the allocation is not available.
Moreover, the production start date and time 317 stores a start date and
15 time of production calculated by the production plan planning apparatus 1
when the order is received. If the processed allocation 318 stores "1", the
allocation has been completed for the received order of this entry, and if the
processed allocation 318 stores "0", the allocation has not been processed
yet.
20 FIG. 3 shows an example of the stock information recording part 32
according to the first embodiment of this invention. The stock information
recording part 32 includes entries each including a stock ID 321 for storing
an identifier of a stock, an item name 322 for storing a name of a product or
a component, a quantity 323 for storing a quantity of the stock, and a
25 production date 324 for storing a date or a time stamp when production of
the product is started. The stock ID 321 is a unique value assigned by the
allocation processing execution part 25.
FIG. 4 shows an example of the allocation information recording part
36. The allocation information recording part 32 includes entries each
12
including an allocation source 361 for storing an identifier of received order
information, production schedule information, or production instruction
information which is an allocation source, an allocation destination 362 for
storing an identifier of production schedule information, production
instruction information, or stock information which is an 5 allocation
destination, and an allocated quantity 363. A first entry of FIG. 4
represents that 25 items are allocated from a production schedule 1 to a
received order 1.
FIG. 5 shows an example of the component information recording
10 part 37. The component information recording part 37 includes entries
each including a component table ID 371 for storing an identifier of a
component table, a parent item name 372 for storing an item name
corresponding to a parent in the component table, and a child item name
373 for storing an item name corresponding to a child in the component
15 table. The component table ID 371 is a unique value set in advance. A
first entry of FIG. 5 represents that an item having a parent item name A is
produced by using an item having a child item name B.
FIG. 6 shows an example of the process information recording part
34. The process information recording part 34 includes entries each
20 including a process ID 341 for storing an identifier of a process, a produced
product 342 for storing a name of a product or a component produced by the
process, and a manufacturing LT 343 for storing a period (lead time)
required to manufacture the product. The process ID 341 is a unique value
set in advance.
25 FIG. 7 shows an example of the production schedule information
recording part 35. The production schedule information recording part 35
includes entries each including a production schedule ID 351 for storing an
identifier of production schedule information, an item name 352 for storing a
name of a product or a component produced by following the production
13
schedule information, a quantity 353 for storing a quantity of the product to
be manufactured, a completion date 354 for storing a scheduled date of
completion of the production, an unavailable allocation 355 for storing an
insufficient quantity of allocation subjects if sufficient allocation subjects
satisfying a received order condition are not available, a production date 5 356
for storing a date or a timestamp when production of the product is started,
and a processed allocation 357 representing whether allocation has been
completed or not for the production schedule information for this entry.
The production schedule ID 341 is a unique value set by the
10 production schedule information acquisition part 24. If the unavailable
allocation 355 is 0, the quantity (or volume) 353 of products or components
to be produced is allocated, and if the unavailable allocation 355 is more
than 0, the unavailable allocation 355 represents a quantity of the products
for which the allocation is not available. If the processed allocation 357
15 stores "1", the allocation has been completed for the production schedule
information of this entry, and if the processed allocation 357 stores "0", the
allocation has not been processed yet.
FIG. 8 shows an example of the production instruction information
recording part 33. The production instruction information recording part 33
20 includes entries each including a production instruction ID 331 for storing
an identifier of production instruction, an item name 332 for storing a name
of a product or a component produced by following the production
instruction, a quantity 333 for storing a quantity of the product to be
manufactured, a completion date 334 for storing a scheduled date of
25 completion of the production, and a production date 335 for storing a date or
a timestamp when production of the product is started. The production
instruction ID 331 is a unique value set by the allocation processing
execution part 25.
FIG. 9 is a flowchart illustrating an example of processing carried out
14
by the received order information acquisition part 21. This processing is
carried out by the processor 4 when an input is requested by the
management terminal apparatus 100. First, in Step S1, the received order
information acquisition part 21 executed by the processor 4 transmits a
received order information input screen to the management 5 terminal
apparatus 100, and receives an input from the management terminal
apparatus 100. In Step S2, the received order information acquisition part
21 analyzes information received from the management terminal apparatus
100. In Step S3, the received order information acquisition part 21
10 determines whether the received order information which has been received
is valid or not based on a result of the analysis. When the received order
information is valid, the received order information acquisition part 21
proceeds to Step S4, and when the received order information includes an
error, the received order information acquisition part 21 returns to Step S1,
15 and prompts an input.
In Step S4, the received order information acquisition part 21 adds a
new entry to the received order information recording part 31, and stores the
received order information which has been received in the added entry.
As a result of this processing, the new received order information
20 input from the management terminal apparatus 100 is stored in the received
order information recording part 31 of the production plan planning
apparatus 1.
FIG. 10 is a flowchart illustrating an example of processing carried
out by the received order condition analysis part 22. This processing is
25 carried out by the processor 4 when new received order information is stored
in the received order information recording part 31. First, in Step S10, the
received order condition analysis part 22 executed on the processor 4
acquires a list of received order information from the received order
information recording part 31.
15
In Step S11, the received order condition analysis part 22 selects an
entry having vacant production start date and time 317 in the received order
information recording part 31, and calculates the oldest date and time in a
period of the production start stored in the received order condition 316 as
the production start date and time. Then, in Step S12, the received 5 order
condition analysis part 22 sorts the received order information recording
part 31 in an ascending order of the production start date and time 317. It
should be noted that in this processing, entries for which the delivery is not
processed (processed allocation 318=0) in the received order information
10 recording part 31 are preferably set as subjects of the processing.
FIG. 11 is a flowchart illustrating an example of processing carried
out by the production schedule information acquisition part 24. This
processing is carried out by the processor 4 when the production plan
planning apparatus 1 receives an input from the input apparatus 6. First,
15 in Step S21, the production schedule information acquisition part 24
executed by the processor 4 transmits a production schedule input screen to
the output apparatus 5 for display, and receives an input from the input
apparatus 6. In Step S22, the production schedule information acquisition
part 24 analyzes information on a production schedule received from the
20 input apparatus 6. In Step S23, the production schedule information
acquisition part 24 determines whether the received production schedule
information is valid or not based on a result of the analysis. When the
production schedule information is valid, the production schedule
information acquisition part 24 proceeds to Step S24, and when the
25 production schedule information includes an error, the production schedule
information acquisition part 24 returns to Step S21, and prompts an input.
In Step S24, the production schedule information acquisition part 24
adds a new entry to the production schedule information 35, and stores the
production schedule information which has been received in the added
16
entry.
As a result of this processing, the new production schedule
information input from the input apparatus 6 is stored in the production
schedule information recording part 31 of the production plan planning
5 apparatus 1.
FIG. 12 is a flowchart illustrating an example of processing carried
out by the allocation processing execution part 25. This processing is
carried out by the processor 4 at a predetermined timing such as a timing
when an administrator of the production plan planning apparatus 1 issues
10 an instruction, a timing when new received order information is stored in the
received order information recording part 31, and a timing when new
production schedule information is stored in the production schedule
information recording part 35.
In Step S31, the allocation processing execution part 25 acquires the
15 received order information sorted in Step S12 from the received order
condition analysis part 22. Then, in Step S32, the allocation processing
execution part 25 determines whether or not an entry for which the
allocation has not been processed, namely, entries having "0" in the
processed allocation 318 in the received order information recording part 31
20 of FIG. 2 exists out of the received order information acquired from the
received order condition analysis part 22. When received order information
for which the allocation has not been processed exists, the allocation
processing execution part 25 proceeds to Step S33, and when received order
information for which the allocation has not been processed does not exist,
25 the allocation processing execution part 25 proceeds to Step S34.
In Step S33, in order to allocate the production schedule information
to the received order information which has not been processed, the
allocation processing execution part 25 sets a parameter (PARM of FIG. 12)
to "received order", and carries out the allocation processing. When the
17
allocation processing is completed for one piece of the received order
information, the allocation processing execution part 25 returns to Step S32,
and repeats the processing. Moreover, in the allocation processing, the
processed allocation 318 of the received order information for which the
5 allocation has been completed is updated to "1".
Then, in Step S34, the allocation processing execution part 25 refers
to the production schedule information recording part 35, and determines
whether or not an entry for which the allocation processing has not been
processed, namely an entry having "0" in the processed allocation 357 of the
10 production schedule information recording part 35 of FIG. 7 exists. When
production schedule information for which the allocation has not been
processed exists, the allocation processing execution part 25 proceeds to
Step S36, and when production schedule information for which the
allocation has not been processed does not exist, the allocation processing
15 execution part 25 finishes the processing.
In Step S36, in order to allocate products or components to the
production schedule information which has not been processed, the
allocation processing execution part 25 sets the parameter (PARM of FIG. 12)
to "production schedule", and carries out the allocation processing. After
20 the allocation processing has been completed for one piece of production
schedule information, the allocation processing execution part 25 returns to
Step S35, and repeats the processing. In the allocation processing, the
processed allocation 357 of the production schedule information for which
the allocation has been completed is updated to "1" as in Step 33.
25 FIGS. 13A and 13B are flowcharts illustrating an example of
processing carried out in the allocation processing. This processing is
called by the allocation processing of Steps S33 and S36 of FIG. 12, and, as
described later, is processing called recursively.
First, in Step S41, the allocation processing execution part 25
18
acquires from the auxiliary storage 3 information corresponding to the
parameter (PARM of FIG. 13A) used to call the allocation processing. For
example, when the parameter is "received order", the allocation processing
execution part 25 refers to the received order information recording part 31,
when the parameter is "production schedule", the allocation 5 processing
execution part 25 refers to the production schedule information recording
part 35, and when the parameter is "production instruction", the allocation
processing execution part 25 refers to the production instruction information
acquisition part 33, thereby acquiring information subject to the allocation
10 processing.
In Step S42, the allocation processing execution part 25 determines
whether a preceding process of the current processing subject exists or not.
On this occasion, when the processing subject is "received order", the
allocation processing execution part 25 searches the process information
15 recording part 34, thereby determining whether a process ID matching the
production product 342 exists or not as the preceding process. When the
processing subject is "production schedule" or "production instruction", the
allocation processing execution part 25 searches the component information
recording part 37 for a component table ID 371 corresponding to a parent
20 item name 372 storing the produced product of the current process as the
preceding process, and, when such a component table ID 371 exists,
determines whether a process ID 341 corresponding to a produced product
342 storing a child item name 373 corresponding to the component table ID
371 exists in the process information recording part 34 or not.
25 When a preceding process exists for the processing subject, the
allocation processing execution part 25 proceeds to Step S43, and when a
preceding process does not exist, the allocation processing execution part 25
finishes the processing.
In Step S43, the allocation processing execution part 25 searches the
19
production schedule information recording part 35 for production schedule
information which can be allocated to the processing subject. Then, the
allocation processing execution part 25 selects the production schedule ID
351 of the retrieved production schedule information. When a plurality of
pieces of production schedule information which can be 5 e allocated are
retrieved, the allocation processing execution part 25 preferentially selects
the production schedule information oldest in the completion date 354 of the
production schedule information recording part 35.
In Step S44, the allocation processing execution part 25 determines
10 whether another piece of production schedule information which can be
allocated to the current processing subject (such as production schedule
information) exists or not. The allocation processing execution part 25
searches the component information recording part 37 for a child item name
373 which corresponds to a preceding process of the current processing
15 subject, and searches the production schedule information recording part 35
for production schedule information matching the child item name 373,
thereby determining whether production schedule information exists or not.
Then, when production schedule information which can be allocated exists,
the allocation processing execution part 25 proceeds to Step S45, and when
20 production schedule information which can be allocated does not exist, the
allocation processing execution part 25 proceeds to Step S50 of FIG. 13B.
In Step S45, the allocation processing execution part 25 sets the
allocable production schedule information to the parameter, and recursively
calls the allocation processing, thereby carrying out the allocation processing
25 for the production schedule information (or production instruction
information).
In Step S46, the allocation processing execution part 25 determines
whether the production time information satisfies the received order
condition or not for the production schedule information for which the
20
allocation processing has been completed by the recursive allocation
processing. On this occasion, the production time information includes the
production start date and the production completion date as described above.
In Step S46, when the production date 356 (production start date) of the
production schedule information recording part 35 is after the 5 production
start date and time 317 of the received order information recording part 31,
and the completion date 354 of the production schedule information
recording part 35 is before the due date 314 of the received order
information recording part 31, the allocation processing execution part 25
10 determines that the production time information satisfies the received order
condition, and proceeds to Step S47. When the production time
information does not satisfy the received order condition, the allocation
processing execution part 25 returns to Step S44, and searches for
production schedule information which can be allocated next.
15 In Step S47, the allocation processing execution part 25 adds an
entry having a production schedule ID 351 satisfying the required condition
as the allocation destination 362, and having the production schedule
information on the preceding process as the allocation source 361 to the
allocation information recording part 36, and stores the quantity of the
20 production schedule information in the allocated quantity 363, thereby
generating allocation information. When the quantity 353 of the production
schedule information is more than the quantity 313 of the received order
information, a difference acquired by subtracting the quantity 313 of the
received order information from the quantity 353 of the production schedule
25 information is a quantity of a product or a component scheduled to be
produced, and is not allocated yet. The products scheduled to be produced
and not allocated can be managed as a stock scheduled to be produced.
Then, in Step S48, the allocation processing execution part 25 takes
over the production start date of the production schedule information
21
corresponding to the allocation information registered in Step S47 to the
following process. This processing duplicates, in the production schedule
information recording part 35, the production date 356 (production start
date) of the production schedule information older in terms of time series to
the production date 356 (production start date) of new production 5 uction schedule
information corresponding to the following process.
In Step S49, the allocation processing execution part 25 determines
whether or not the allocated quantity 363 of the allocation information
recording part 36 satisfies the quantity 313 (required quantity)
10 corresponding to the received order ID 311 of the received order information
recording part 31. When the allocated quantity 363 satisfies the required
quantity, the allocation processing execution part 25 finishes the processing.
On the other hand, when the allocated quantity 363 does not satisfy the
required quantity, the allocation processing execution part 25 returns to
15 Step S44, and searches for production schedule information which can be
allocated next.
FIG. 13B illustrates processing carried out when the allocation
processing execution part 25 determines in Step S44 that production
schedule information which can be allocated next does not exist. In Step
20 S50, the allocation processing execution part 25 generates production
instruction information for the production schedule information having the
production schedule ID 351 selected in Step S43, which corresponds to the
preceding process. In order to generate the production instruction
information, the allocation processing execution part 25 acquires the item
25 name 352 corresponding to the production schedule ID 351 of the
production schedule information recording part 35, and extracts
components (or materials) required for the item name 352 from the
component information recording part 37. For example, if the item name
352 of the production schedule information is "A", the allocation processing
22
execution part 25 extracts a component having "B" in the child item name
373 from an entry having "A" in the parent item name 372 in the component
information recording part 37. Then, the allocation processing execution
part 25 extracts a component having "C" in the child item name 373 from an
entry having "B" in the parent item name 372. Then, 5 , the allocation
processing execution part 25 repeats the processing until an entry having
the child item name 373 in the parent item name 372 no longer exists.
The allocation processing execution part 25 generates production
instructions for the component "B" for manufacturing the product "A" in the
10 production schedule information, and for the component (or the raw
material) "C" for manufacturing the component "B". On this occasion, the
allocation processing execution part 25 refers to the process information
recording part 34 to acquire the process IDs 341 and the manufacturing lead
times (LTs in FIG. 6) for the components "B" and "C". On this occasion, the
15 allocation processing execution part 25 extracts a process ID 341: "process
2" and a manufacturing lead time 343: "2 days" for the component "B", and a
process ID 341: "process 3", and a manufacturing lead time 343: "1 day" for
the component "C".
The allocation processing execution part 25 uses the production start
20 of the existing production schedule information as a start point to generate
production instruction information for the component "B" in a temporally
backward direction, and then generates production instruction information
for the component "C". In other words, in the example in which the
production schedule 2 is allocated to the received order 1, which is currently
25 focused on, the production date 335 representing the production start date
of the component "C" is determined from a sum of the manufacturing lead
times 343 so that the completion date 334 of the component "B" is set before
the production start of the product "A", and the completion date 334 of the
component "C" is set before the production start of the product "B". In this
23
case, the production of the component "C" takes "1 day", the production of
the component "B" takes "2 days", and thus, as shown in FIG. 8, entries for
the components "B" and "C" are generated in the production instruction
information recording part 33 so that the production of the component "C" is
started three days before the production start of the product "A". In 5 n this
example, entries "production instruction 1" and "production instruction 2"
are added to the production instruction IDs 331 of the production
instruction information recording part 33. Values satisfying the quantities
353 of the production schedule information selected in Step S43 is set to the
10 quantities in these entries.
Then, in Step S51, the allocation processing execution part 25 uses
as parameters the newly generated "production instruction 1" and
"production instruction 2" to recursively call the allocation processing of
FIGS. 13A and 13B, thereby allocating "production instruction 1" to
15 "production schedule 2", and allocating "production instruction 2" to
"production instruction 1".
Then, in Step S52, the allocation processing execution part 25
determines whether the production instruction information for which the
allocation processing has been completed satisfies the received order
20 condition. In this determination, the allocation processing execution part
25 reads corresponding production instruction information and production
schedule information from the production instruction information recording
part 33, and if the completion date 334 when the production of the
component "C" used as the raw material is completed is before the
25 production start date (completion date-manufacturing lead time) of the
component "B", and the completion date 334 when the production of the
component "B" is completed is before the production start date (completion
date 354-manufacturing lead time 343) of the product "A", the allocation
processing execution part 25 determines that the production instruction
24
information satisfies the received order condition, and proceeds to Step S53.
On the other hand, if the production time information of the production
instruction information does not satisfy the received order condition, the
allocation processing execution part 25 proceeds to Step S55.
In Step S53, the allocation processing execution part 25 stores th5 e
allocation information in the allocation information recording part 36 based
on the production instruction information for which the allocation is carried
out in Step S51. Then, in Step S54, the allocation processing execution
part 25 sets the production start date of the component C, the production of
10 which is started first, to the production dates 335 and 356 of the
corresponding entries of the production instruction information recording
part 33 and the production schedule information recording part 35 for the
respective processes from the component (or raw material) "C" to the product
"A", and controls the component "B", the process of which is the next to the
15 process of the component "C" and the product "A", the process of which is
next to the process of the component "B", to take over the oldest production
start date. In other words, the oldest value out of the production start dates
of the raw materials and the components is taken over to the production
date 356 representing the production start date of the end product "A".
20 On the other hand, in Step 55, when the production time information
of the production instruction information cannot satisfy the received order
condition in Step S52, the allocation to the production schedule information
fails, the allocation processing execution part 25 stores a quantity of the
components to which the production schedule information cannot be
25 allocated in the allocation information recording part 36. Then, in Step S56,
the allocation processing execution part 25 deletes the production
instruction information to which the allocation cannot be carried out from
the production instruction information recoding part 33, and finishes the
processing. On this occasion, the allocation processing execution part 25
25
may notify the output apparatus 5 and the management terminal apparatus
100 of the failed allocation.
As a result of the processing, the production schedule information (or
production instruction information) is allocated to the received order
information, and the production instruction information or the 5 production
schedule information for the components (or the raw materials) to produce
the product specified by the production schedule information is further
allocated. Then, for each piece of the production schedule information and
production instruction information, the allocation processing execution part
10 25 determines the production start date and the production completion date
from the parent/child relationship between the product and the components
set in the component information recording part 37, and the process IDs and
the manufacturing lead times of the produced products set in the process
information recording part 34. The allocation processing execution part 25
15 sequentially determines the production start date and the production
completion date for each process constituting a preceding process starting
from the production schedule information (or production instruction
information) allocated to the received order information. Then, when the
allocation processing execution part 25 reaches a process constituting the
20 start point of the production, the allocation processing execution part 25
controls the following process to take over the production start date of the
process constituting the start point of the production and sets the
production start date as the production start date of the end product. In
other words, the allocation processing execution part 25 sequentially
25 determines production schedules from the production schedule information
(or the production instruction information) allocated to the received order
information, and then controls the production start date of the process
which constitutes the start point of the production start to be taken over
from the following process to the end product.
26
FIG. 14 is a screen image illustrating an example of a screen output
on the display apparatus of the management terminal apparatus 100 in Step
S1 of FIG. 9, and on the output apparatus 5 of the production plan planning
apparatus 1 in Step S21 of FIG. 11
In FIG. 5 G. 14, a screen 210 for received orders and production schedules
is vertically divided into two parts, and includes a display area 310 for
displaying the received order information and a display area 350 for
displaying the production schedule information.
The received order information 3110 is displayed in time series on the
10 display area 310. In the received order information 3110, the received order
ID 311, the item name 312, the quantity 313, and the due date 314 are
displayed in the stated order from a top of FIG. 14.
The production schedule information 3510 is displayed in time series
on the display area 350. In the production schedule information 3510, the
15 production schedule ID 331, the item name 332, the quantity 333, and the
production date (production start date) 334 are displayed in the stated order
from the top of FIG. 14.
A received order information input button 211 and a received order
information detail button 212 are arranged on a right side of the display area
20 310. When the received order information input button 211 is operated by
the input apparatus such as a mouse, the screen transitions to the received
order information input screen of FIG. 15. When the received order
information detail button 212 is operated, the screen transitions to a
received order information detail display screen of FIG. 16.
25 A production schedule information input button 213 and a
production schedule information detail button 214 are arranged on a right
side of the display area 350. When the production schedule information
input button 213 is operated by the input apparatus such as a mouse, the
screen transitions to a production schedule information input screen of FIG.
27
17. When the production schedule information detail button 214 is
operated, the screen transitions to a production schedule information detail
display screen of FIG. 18.
FIG. 14 illustrates an example in which the received order
information and the production schedule information are input/output in 5 a
single screen or window, but the display area 310 for displaying and
inputting the received order information and the display area 350 for
displaying and inputting the production schedule information may be
different screens so that the display area 310 is output to the display
10 apparatus of the management terminal apparatus 100 and the display area
350 is output to the output apparatus 5, which is not shown.
Moreover, the screen of FIG. 14 may be output to the output
apparatus 5 or the management terminal apparatus 100 after the processing
of FIGS. 13A and 13B is finished.
15 FIG. 15 is a screen image illustrating an example of the received
order information input screen. The received order information input screen
2100 includes an input field 2101 for a product name, an input field 2102
for inputting a date and time of a time limit of a delivery, an input field 2103
for a quantity, and an input field 2104 for inputting the number of days of
20 the received order condition.
New received order information is stored in the received order
information recording part 31 by operating a run button after inputs from
the management terminal apparatus 100 or the input apparatus 6 to the
respective input fields 2101 to 2104.
25 FIG. 16 is a screen image illustrating an example of a received order
information detail display screen 3100. The received order information
detail display screen 3100 includes an area 3101 for displaying received
order information, and production schedule information and production
instruction information corresponding to the received order information in a
28
sequence of time series and processes, and an area 3102 for displaying
allocation information on products of the received order.
In the area 3101, a vertical axis represents a process, and a
horizontal axis represents a time series. The illustrated example represents
an example of a received order ID="received order 3" of producing 5 50
products A having a production start date after October 1. The component
B (process 3) is manufactured from the component C in the process 3, and
the product A is manufactured from the component B in the process 1 based
on the component information recording part 37 and the process information
10 recording part 34. As the result of the allocation processing described
above, the component C in the process 1 is produced by the production
instruction 2 on October 1, the component B in the process 2 is produced by
the production instruction 1 from October 2 to 3, and the product A in the
process 3 is produced by the production schedule 2 on October 4.
15 Then, for each of a production schedule 2 for the product A allocated
to a received order 3, the production instruction 1 for the component B
allocated to the production schedule 2, and the production instruction 2 for
the product C allocated to the production instruction 1, a production date
(production start date), a received order condition, a production completion
20 date, an available number of allocations ("allocation OK" of FIG. 16), and an
unavailable number of allocation ("allocation NG" of FIG. 18) are displayed in
the area 3102.
FIG. 17 is a screen image illustrating an example of the production
schedule information input screen. The production schedule information
25 input screen 2400 includes an input field 2401 for a product name, an input
field 2402 for inputting a date and time of a production completion, and an
input filed 2403 for a quantity.
New production schedule information is stored in the production
schedule information recording part 35 by operating a run button after
29
inputs from the management terminal apparatus 100 or the input apparatus
6 to the respective input fields 2401 to 2403.
FIG. 18 is a screen image illustrating an example of a production
schedule information detail display screen 3200. The production schedule
information detail display screen 3200 includes an area 3201 for 5 displaying
production schedule information, and production instruction information or
stock information corresponding to the production schedule information in a
sequence of time series and processes, and an area 3202 for displaying
allocation information on a product or a component to be produced.
10 In the area 3201, a vertical axis represents a process, and a
horizontal axis represents a time series. The illustrated example represents
an example of a production schedule ID="production schedule 4" of
producing 50 products D having a production start date after September 28.
The product D is produced from a product E in a process 2 based on the
15 component information recording part 37 and the process information
recording part 34. The products D and E are not shown in the component
information recording part 37 of FIG. 5 and the process information
recording part 34 of FIG. 6.
FIG. 19 is a time chart illustrating an example of allocations of a
20 received order, components, and a product. FIG. 19 illustrates an example
in which new production instructions 1 and 2 are produced and are
allocated by the allocation processing of FIGS. 13A and 13B for a received
order ID="received order 1". In FIG. 19, a vertical axis represents a process,
and a horizontal axis represents a time series.
25 First, in the allocation processing, for 50 products A having a due
date 314 of October 6 as a received order ID= "received order 1", the
production schedule information recording part 35 is searched for
production schedule information which can be allocated. In the illustrated
example, a production schedule 1 based on which the production is to be
30
completed (completion date 354) on October 4 and a production schedule 2
the completion date of which is October 6 are extracted. On this occasion,
in Step S43, the allocation processing execution part 25 selects the
production schedule 1 having the oldest completion date 354, and allocates
the production schedule 1 to the received order ID="received order 1"5 .
Then, the allocation processing execution part 25 acquires
information on the component B required to produce the product A from the
component information recording part 37. Then, the allocation processing
execution part 25 searches for a production schedule which can be allocated
10 to the production schedule 1. A production schedule for the component
(material in FIG. 19) B which can be allocated to the production schedule 1
does not exist, and the allocation processing execution part 25 thus newly
generates the production instruction 1 for producing the component B as a
preceding process of the production schedule 1 (S50). Then, the allocation
15 processing execution part 25 allocates the production instruction 1 to the
production schedule 1 (S51). On this occasion, the allocation processing
execution part 25 refers to the process information recording part 34,
thereby acquiring such a condition that the manufacturing lead time of the
produced product 342 of "B" is two days, and sets October 2, which is two
20 days before the production start date of October 4 of the production
schedule 1, to the production start date of the component B.
Then, the allocation processing execution part 25 acquires
information on the component C required to produce the component B from
the component information recording part 37. Then, the allocation
25 processing execution part 25 searches the production schedule information
recording part 35 for a production schedule which can be allocated to the
production instruction 1. A production schedule for the component (raw
material in FIG. 19) C which can be allocated to the production instruction 1
does not exist, and the allocation processing execution part 25 thus newly
31
generates the production instruction 2 for producing the component C as a
preceding process of the production instruction 1 (S50). Then, the
allocation processing execution part 25 allocates the production instruction
2 to the production instruction 1 (S51). On this occasion, the allocation
processing execution part 25 refers to the process information recording par5 t
34, thereby acquiring such a condition that the manufacturing lead time of
the produced product 342 of "C" is one day, and sets October 1, which is one
day before the production start time of October 2 of the production
instruction 1, to the production start date of the component C.
10 Then, the allocation processing execution part 25 determines whether
or not the production start date="October 1" of the component C satisfies the
received order condition 316 of "start production within 5 days" (S52). Then,
the allocation processing execution part 25 sets the production start date
(production date) of the start point of the production of the product A to
15 October 1, takes over the production start date to the production start date
(production date 335) of the production instruction 1, which is the following
process of the production instruction 2, and further takes over the
production start date of the production instruction 2 to the production date
356 of the production schedule 1, which is the following process of the
20 production instruction 1.
As described above, according to this invention, the production
schedule information is retrieved from the received order information, the
preceding processes for components constituting the product A are
sequentially selected and generated for the allocation, and the processes and
25 the dates for producing the product A are sequentially determined toward
the preceding processes. Then, a first production start date or production
start time of the component out of the components constituting the product
A is set to the production start date of the product A, and is sequentially
taken over toward the following processes. In other words, after the
32
processes are determined toward the preceding processes, the production
start date (production time information) of the first component is
sequentially taken over toward the following processes, and is set as the final
production start date of the product.
In this way, the production start date or the production start time 5 of
the first component or raw material out of the components (raw materials or
materials) constituting the product A is taken over to the following processes,
and is treated as the production start date of the product A. As a result,
even when elapsed days or an elapsed time from the production start for a
10 food or the like is included in the received order condition, the production
plan can be automatically generated.
Such an example that the various tables (the received order
information recording part 31 to the component information recording part
37) are stored in the auxiliary storage 3 has been described in the first
15 embodiment, but these tables may be stored in the main storage 2.
Moreover, such an example that a production plan having the
production start date satisfying the received order condition is generated has
been described in the first embodiment, but a condition for time may be
added as the received order information, and such a production plan that
20 the production start date and time satisfy the received order condition may
be generated.

FIGS. 20A and 20B illustrate a second embodiment of this invention,
and are flowcharts representing processing carried out by the allocation
25 processing execution part. FIG. 20A illustrates a first half of the processing
carried out by the allocation processing execution part, and FIG. 20B
illustrates a last half of the processing carried out by the allocation
processing execution part.
In the second embodiment, such a configuration that products and
33
components (or raw materials and materials) in stock are used is added to
the configuration of the first embodiment, and the other configurations are
the same as those of the first embodiment.
The processing of FIGS. 20A and 20B is processing called by the
allocation processing in Steps S33 and S36 of FIG. 12 as in FIGS. 13A 5 and
13B according to the first embodiment, and is processing recursively called
as in the first embodiment.
First, in Steps S61 and S62, as in Steps S41 and S42 of FIG. 13A
according to the first embodiment, the allocation processing execution part
10 25 acquires from the auxiliary storage 3 the information corresponding to
the parameter (PARM of FIG. 20A) when the allocation processing is called
(S61), and determines whether a preceding process exists for the current
processing subject or not (S62). When a preceding process exists for the
processing subject, the allocation processing execution part 25 proceeds to
15 Step S63, and when a preceding process does not exist, the allocation
processing execution part 25 finishes the processing.
In Step S63, the allocation processing execution part 25 searches the
stock information recording part 32 for stock information which can be
allocated to the processing subject. Then, the allocation processing
20 execution part 25 selects the stock ID 321 of the retrieved stock information.
When a plurality of pieces of stock information which can be allocated exist,
the allocation processing execution part 25 preferentially selects the stock
information oldest in the production date 324 of the stock information
recording part 32.
25 In Step S64, the allocation processing execution part 25 determines
whether another piece of stock information which can be allocated to the
current processing subject (such as production schedule information) exists
or not. In this determination, the allocation processing execution part 25
determines whether another piece of stock information which can be
34
allocated to the current processing subject (such as production schedule
information) exists or not. The allocation processing execution part 25
searches the component information recording part 37 for a child item name
373 which is a preceding process of the current processing subject, and
searches the stock information recording part 32 for stock 5 ock information
matching the child item name 373, thereby determining whether stock
information exists or not. Then, when the stock information which can be
allocated exists, the allocation processing execution part 25 proceeds to Step
S65, and when the stock information which can be allocated does not exist,
10 the allocation processing execution part 25 proceeds to Step S43 of FIG.
20B.
In Step S65, the allocation processing execution part 25 acquires the
production date (production start date) 324 as the production time
information from the stock information recording part 32 for the stock
15 information which can be allocated, and determines whether the production
time information satisfies the received order condition or not. On this
occasion, the production time information of the stock information recording
part 32 is only the production date (production start date) 324. Thus, when
the production date (production start date) 324 of the production schedule
20 information recording part 35 is after the production start date 317 of the
received order information recording part 31, the allocation processing
execution part 25 determines that the received order condition is satisfied.
Then, when the production time information satisfies the received order
condition, the allocation processing execution part 25 proceeds to Step S66.
25 On the other hand, when the stock information does not satisfy the received
order condition, the allocation processing execution part 25 returns to Step
S64, and searches for stock information which can be allocated next.
In Step S66, the allocation processing execution part 25 adds an
entry having the stock information ID 321 satisfying the required condition
35
as the allocation destination 362 and having the production schedule
information (or the production instruction information) on the preceding
process as the allocation source 361 to the allocation information recording
part 36, and stores the quantity stored in the stock information recording
part (or the production schedule information recording part 35) in th5 e
allocated quantity 363, thereby generating allocation information. When
the quantity 353 stored in the production schedule information (stock
information) is more than the quantity 313 stored in the received order
information, a difference acquired by subtracting the quantity 313 stored in
10 the received order information from the quantity 353 stored in the stock
information is a quantity of a product or a component scheduled to be
produced, and is not allocated yet. The products in stock and not allocated
can be managed as a stock in the stock information recording part 32.
Then, in Step S67, the allocation processing execution part 25 takes
15 over the production start date of the stock information corresponding to the
allocation information registered in Step S66 to a following process. This
processing duplicates the production date (production start date) 324 of the
stock information recording part 32 to the production date 356 (production
start date) of a production schedule or the production date 335 (production
20 start date) of a production instruction constituting the following process.
In Step S68, the allocation processing execution part 25 determines
whether or not the allocated quantity 363 of the allocation information
recording part 36 satisfies the quantity 313 (required quantity)
corresponding to the received order ID 311 of the received order information
25 recording part 31. When the allocated quantity 363 satisfies the required
quantity, the allocation processing execution part 25 finishes the processing.
On the other hand, when the allocated quantity 363 does not satisfy the
required quantity, the allocation processing execution part 25 returns to
Step S64, and searches for stock information which can be allocated next.
36
Processing of Steps S43 to S56 of FIG. 20B to which the allocation
processing execution part 25 proceeds when it is determined in Step S64
that the stock information which can be allocated next does not exist is the
same as the processing of FIGS. 13A and 13B according to the first
embodiment. In 5 n other words, after stock information which can be allocated
to the processing subject is retrieved, when stock information which can be
allocated no longer exists, production schedule information which can be
allocated to the processing subject is retrieved. Then, when production
schedule information which can be allocated to the processing subject no
10 longer exists, production instruction information is generated.
As described above, according to the second embodiment of this
invention, products or components which can be allocated are retrieved
based on the received order information from the stock information and the
production schedule information in the stated order, and when stock
15 information exists, the stock information is allocated to the products or
components in priority to the production schedule information. Then, the
allocation processing execution part 25 sequentially selects or generates
processes for the components constituting the product A, and sequentially
determines processes and dates (production periods) of the components to
20 be produced toward the preceding processes. Then, a first production start
date or production start time of the component out of the components
constituting the product A is set to the production start date of the product
A, and is sequentially taken over toward the following processes. In other
words, after the processes are determined toward the preceding processes,
25 the production start date of the first component is sequentially taken over
toward the following processes, and is set as the final production start date
of the product.
In this way, the first production start date or production start time of
a component (raw material or material) out of the components constituting
37
the product A is taken over to the following processes, and is treated as the
production start date of the product A. As a result, even when elapsed days
or an elapsed time from the production start for a food or the like is included
in the received order condition, the production plan can be automatically
5 generated.
38
WE CLAIM:
1. A production plan planning method for storing, by a computer
comprising a processor and a storage, production schedule information on at
least one first component constituting a product and at least one second
component constituting the at least one first component, in a productio5 n
schedule information storage part of the storage, receiving an order for the
product, and generating a production process for the product,
the production plan planning method comprising:
a first step of receiving, by the computer, the order including
10 production time information on the product in a received order condition as
received order information;
a second step of searching, by the computer, the production schedule
information storage part for production schedule information on the product
stored in the received order information;
15 a third step of allocating, by the computer, production schedule
information on each process for the at least one first component to the
retrieved production schedule information; and
a fourth step of controlling, by the computer, the allocated production
schedule information on the each process to take over the production time
20 information,
the third step comprising allocating production schedule information
satisfying the production time information included in the received order
condition of the received order information to the each process,
the fourth step comprising controlling the respective allocated
25 processes to sequentially take over production time information on a first
process of the product.
2. The production plan planning method according to claim 1,
wherein the third step comprises searching stock information storage part
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for storing stock information on the at least one first component for stock
information satisfying the production time information included in the
received order condition, and, when the stock information satisfying the
production time information included in the received order condition exists,
allocating the stock information to the process in priority to the 5 production
schedule information.
3. The production plan planning method according to claim 1,
wherein the third step comprises newly generating, when the production
10 schedule information satisfying the production time information included in
the received order condition of the received order information is not allocable
to the process, production schedule information to be allocated to the
process.
15 4. The production plan planning method according to claim 2,
wherein the third step comprises newly generating, when the production
schedule information and the stock information satisfying the production
time information included in the received order condition of the received
order information are not allocable to the process, production schedule
20 information to be allocated to the process.
5. The production plan planning method according to claim 3, further
comprising outputting, when the production schedule information satisfying
the production time information included in the received order condition of
25 the received order information is not allocable to the process, a notification
that the allocation is unavailable.
6. The production plan planning method according to claim 2,
wherein the third step comprises allocating, when a plurality of pieces of
40
stock information satisfying the production time information included in the
received order condition exist, stock information oldest in the production
time information to the process.
7. The production plan planning method according to claim 5 1, further
comprising a fifth step of outputting, by the computer, screen information
for displaying the received order information, which has been received, and
the allocated production schedule information as a time series.
10 8. A production plan planning apparatus, comprising a processor and
a storage, for storing production schedule information on at least one first
component constituting a product and at least one second component
constituting the at least one first component, in a production schedule
information storage part of the storage, receiving an order for the product,
15 and generating a production process for the product,
the production plan planning apparatus further comprising:
a received order information acquisition part for receiving the order
including production time information on the product in a received order
condition as received order information; and
20 an allocation processing part for searching the production schedule
information storage part for production schedule information on the product
stored in the received order information, allocating production schedule
information on each process for the at least one first component to the
retrieved production schedule information, and controlling the allocated
25 production schedule information on the each process to take over the
production time information,
the allocation processing part being configured to allocate production
schedule information satisfying the production time information included in
the received order condition of the received order information to the each
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process, and control the respective allocated processes to sequentially take
over production time information on a first process of the product.
9. A non-transitory computer-readable storage medium having stored
thereon a program for controlling a computer comprising a processor and 5 a
storage to store production schedule information on at least one first
component constituting a product and at least one second component
constituting the at least one first component, in a production schedule
information storage part of the storage, receive an order for the product, and
10 generate a production process for the product,
the program further controlling the computer to execute:
a first procedure of receiving the order including production time
information on the product in a received order condition as received order
information;
15 a second procedure of searching the production schedule information
storage part for production schedule information on the product stored in
the received order information;
a third procedure of allocating production schedule information on
each process for the at least one first component to the retrieved production
20 schedule information; and
a fourth procedure of controlling the allocated production schedule
information on the each process to take over the production time
information,
the third procedure comprising allocating production schedule
25 information satisfying the production time information included in the
received order condition of the received order information to the each
process,
the fourth procedure comprising controlling the respective allocated
processes to sequentially take over production time information on a first
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process of the product.
10. The program according to claim 9, wherein the third procedure
comprises searching stock information storage part for storing stock
information on the at least one first component for 5 stock information
satisfying the production time information included in the received order
condition, and, when the stock information satisfying the production time
information included in the received order condition exists, allocating the
stock information to the process in priority to the production schedule
10 information.
11. The program according to claim 9, wherein the third procedure
comprises newly generating, when the production schedule information
satisfying the production time information included in the received order
15 condition of the received order information is not allocable to the process,
production schedule information to be allocated to the process.
12. The program according to claim 10, wherein the third procedure
comprises newly generating, when the production schedule information and
20 the stock information satisfying the production time information included in
the received order condition of the received order information are not
allocable to the process, production schedule information to be allocated to
the process.
25 13. The program according to claim 11, wherein the program controls
the computer to execute outputting, when the production schedule
information satisfying the production time information included in the
received order condition of the received order information is not allocable to
the process, a notification that the allocation is unavailable.
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14. The program according to claim 10, wherein the third procedure
comprises allocating, when a plurality of pieces of stock information
satisfying the production time information included in the received order
condition exist, stock information oldest in the production time 5 me information
to the process.
15. The program according to claim 9, wherein the program further
controls the computer to execute a fifth procedure of outputting screen
10 information for displaying the received order information, which has been
received, and the allocated production schedule information as a time series.