Material supply system and material supply method

Abstract

The present invention provides a material supply system and a material supply method. When the supply of materials used at a plurality of production sites is stopped, a shortage amount calculation unit calculates the shortage amount of the shortage materials for each of the plurality of production sites by using usage information, production plans, and surplus information. An inventory center determination unit uses inventory information, movement information, and the shortage amount to determine an inventory center that supplies the shortage materials to each of the plurality of production sites in the shortest way.

Description

Technical Field

[0001] The present invention relates to a material supply system and a material supply method. Background Art

[0002] Japanese Patent Laid-Open No. 2003-122821 discloses a distribution arrangement method. The distribution arrangement method disclosed in Japanese Patent Laid-Open No. 2003-122821 retrieves, for each of a plurality of equipment centers that perform inventory management of parts, inventory information related to parts currently in stock, delivery vehicle information related to delivery vehicles that can be dispatched for delivery, and delivery time information required for part delivery when a delivery dispatch is made, in response to part request information. Further, the distribution arrangement method disclosed in Japanese Patent Laid-Open No. 2003-122821 automatically selects, from the retrieval results, an equipment center that can deliver a requested part to a part request destination most quickly and makes a distribution arrangement. Summary of the Invention

[0003] Materials such as parts for products are supplied to production sites that produce products. In this case, when the supply of a material is stopped due to the non-supply of the material and the material is a common material used in a plurality of production sites, a shortage of the material (common material) occurs in the plurality of production sites. In contrast, in Japanese Patent Laid-Open No. 2003-122821 described above, since the case where there are a plurality of part request destinations is not assumed, when there is a shortage of a common material, it may not be possible to supply the common material to each of the plurality of production sites in the shortest possible time. Therefore, it may not be possible to reduce the impact on the plurality of production sites.

[0004] The present invention provides a material supply system and a material supply method capable of reducing the impact on each production site when the supply of a material used in each of a plurality of production sites is stopped.

[0005] The material supply system according to the present invention includes: a shortage amount calculation unit that calculates, for each of a plurality of production sites, a shortage amount of a shortage material when the supply of a material used in the plurality of production sites is stopped, using usage information related to the use of the shortage material, which is the material whose supply has stopped, a production plan of a product that uses the shortage material in each of the plurality of production sites, and margin information indicating a margin of the shortage material in each of the plurality of production sites; and an inventory center determination unit that determines an inventory center that supplies the shortage material to each of the plurality of production sites in the shortest possible time, using inventory information related to the shortage material in each of a plurality of inventory centers that store the shortage material, movement information, which is information for obtaining the time required for movement between each of the plurality of production sites and each of the plurality of inventory centers, and the shortage amount.

[0006] In addition, the material supply method involved in the present invention includes: when the supply of materials used at multiple production sites is stopped, using the usage information related to the usage of the material whose supply is stopped, i.e., the shortage material, the production plan of the products using the shortage material at each of the multiple production sites, and the surplus information indicating the surplus of the shortage material at each of the multiple production sites, calculating the shortage amount of the shortage material for each of the multiple production sites; and using the inventory information related to the shortage material at each of the multiple inventory centers storing the shortage material, the information for obtaining the time required for movement between each of the multiple production sites and each of the multiple inventory centers, i.e., the movement information, and the shortage amount, determining the inventory center that supplies the shortage material to each of the multiple production sites in the shortest way.

[0007] With such a structure, it is possible to supply the shortage materials in the required amount from the inventory center to each production site for each of the multiple production sites in the shortest way. Therefore, even when the supply of materials used at each of the multiple production sites is stopped, the present invention can reduce the impact on each production site.

[0008] In addition, preferably, the shortage amount calculation unit calculates the shortage amount of the shortage material, i.e., the shortage amount, that is insufficient at each of the multiple production sites within a specified period.

[0009] By using the shortage amount calculated in this way to determine the inventory center, it is possible to appropriately supply the shortage materials in the amount that is insufficient within the specified period to each production site.

[0010] In addition, preferably, there is also a distribution planning unit that makes a distribution plan for supplying the shortage material from the determined inventory center to each of the multiple production sites.

[0011] With such a structure, it is possible to appropriately distribute the shortage materials from the inventory center to the production sites.

[0012] In addition, preferably, the distribution planning unit interrupts the distribution plan related to the distribution of other materials different from the shortage material to make the distribution plan for the shortage material.

[0013] According to such a structure, since there is no need to prepare vehicles only for distributing the shortage materials, it is possible to efficiently make the distribution plan.

[0014] Further, preferably, in the distribution plan for distributing the other materials from the material factory that produces the other materials to the production site, the distribution planning department makes the vehicle that distributes the other materials from the material factory to the production site detour to the inventory center to carry out the distribution plan for the shortage materials.

[0015] According to such a structure, it is possible to use the existing distribution plan that is currently distributing from the material factory to the production site to distribute the shortage materials. Therefore, the shortage materials can be distributed efficiently.

[0016] Further, preferably, in the distribution plan for distributing the other materials from the material factory that produces the other materials to the inventory center, the distribution planning department makes the return trip of the vehicle that has distributed the other materials to the inventory center detour to the production site to carry out the distribution plan for the shortage materials.

[0017] According to such a structure, it is possible to use the existing distribution plan that is currently distributing from the material factory to the inventory center to distribute the shortage materials. Therefore, the shortage materials can be distributed efficiently.

[0018] Further, preferably, the inventory center is a logistics warehouse that supplies materials to the market.

[0019] According to such a structure, by using the logistics warehouse as the inventory center, there is no need to separately set up an inventory center for supplying materials to the production site.

[0020] According to the present invention, it is possible to provide a material supply system and a material supply method that can reduce the impact on each production site in the case of a supply stop of materials used in each of a plurality of production sites. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Hereinafter, the features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will be described with reference to the accompanying drawings, in which like reference numerals denote like elements, and wherein:

[0022] Figure 1 is a diagram for explaining the outline of the present embodiment.

[0023] Figure 2 is a diagram for explaining the outline of the present embodiment.

[0024] Figure 3 is a diagram showing the hardware structure of the material supply system according to Embodiment 1.

[0025] Figure 4 is a functional block diagram showing the structure of the material supply system according to Embodiment 1.

[0026] Figure 5It is a diagram illustrating the product information stored in the product information storage unit according to Embodiment 1.

[0027] Figure 6 It is a diagram illustrating the production plan stored in the production plan storage unit according to Embodiment 1.

[0028] Figure 7 It is a diagram illustrating the remaining quantity information stored in the remaining quantity information storage unit according to Embodiment 1.

[0029] Figure 8 It is a diagram illustrating the inventory information stored in the inventory information storage unit according to Embodiment 1.

[0030] Figure 9 It is a diagram illustrating the distribution information stored in the distribution information storage unit according to Embodiment 1.

[0031] Figure 10 It is a diagram illustrating the movement information stored in the movement information storage unit according to Embodiment 1.

[0032] Figure 11 It is a diagram illustrating the material usage information according to Embodiment 1.

[0033] Figure 12 It is a flowchart showing the material supply method executed by the material supply system according to Embodiment 1.

[0034] Figure 13 It is a flowchart showing the material supply method executed by the material supply system according to Embodiment 1.

[0035] Figure 14 It is a flowchart showing the material supply method executed by the material supply system according to Embodiment 1.

[0036] Figure 15 It is a flowchart showing the material supply method executed by the material supply system according to Embodiment 1.

[0037] Figure 16 It is a diagram for explaining the interruption of the normal distribution plan for distributing other materials from the material factory to the production site with insufficient materials.

[0038] Figure 17 It is a diagram for explaining the interruption of the normal distribution plan for distributing other materials from the material factory to the inventory center with insufficient materials. Detailed implementation mode

[0039] (Embodiment 1)

[0040] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. For the sake of clarity, the following descriptions and drawings are appropriately omitted and simplified. In addition, in each drawing, the same reference numerals are assigned to the same elements, and repeated descriptions are omitted as needed.

[0041] <Summary>

[0042] Before describing Embodiment 1, the summary of the embodiments will be described.

[0043] Figure 1 And Figure 2 are diagrams for explaining the summary of the present embodiment. Figure 1 is a diagram showing the logistics in normal times. The solid arrows represent the logistics related to the product. In addition, the dashed arrows represent the logistics related to the supplies. In addition, in this specification, the so-called "normal times" refers to the situation where the supply stop of the materials described later does not occur.

[0044] Here, in this specification, the so-called "product" is an article produced using one or more materials. And the "material" is used in the production of the product. For example, the "material" is a component that constitutes the product. For example, when the product is an automobile, the materials are the transmission differential, the transmission, the electronic control device, the gears, the bolts, and the nuts, etc. In addition, the so-called "supplies" are items supplied in the after-sales service of the product after the product is provided to the consumer. For example, the supplies are spare parts or service parts.

[0045] As Figure 1 illustrated, as the bases constituting the logistics, there are a material factory 52, a production base 54, an inventory center 56, and sales stores 64 and 66. In addition, in Figure 1 one material factory 52, one production base 54, and one inventory center 56 are shown respectively, but in reality, there may be multiple material factories 52, production bases 54, and inventory centers 56 respectively.

[0046] The material factory 52 is a factory that produces the material 32. The material factory 52 is, for example, a component factory. The material factory 52 is managed by a supplier that supplies the material 32 to the manufacturer that produces the product 34.

[0047] The production base 54 is a base that produces the product 34 using the material 32. For example, when the product is an automobile, the production base 54 corresponds to an automobile factory or its production line. The production base 54 is managed by the manufacturer that produces the product 34.

[0048] The inventory center 56 is a base for storing the materials 32 as supplies. The inventory center 56 is, for example, a logistics warehouse. Here, the inventory center 56 can store materials that are substantially the same as the materials 32 used in the production of the product 34 at the production base 54. The inventory center 56 can be managed by the manufacturer that produces the product 34.

[0049] The sales store 64 is a base for providing the product 34 produced at the production base 54 to consumers. In addition, the sales store 66 is a base for providing the materials 32 stored in the inventory center 56 as supplies for the product 34 to consumers, that is, the market. In other words, the logistics warehouse serving as the inventory center 56 supplies the materials 32 to the market. Here, the sales store 64 and the sales store 66 can also be the same as each other. That is, for example, the sales store 64 that is a car dealership can also supply the materials 32 as supplies to consumers.

[0050] The materials 32 produced in the materials factory 52 are supplied (delivered) to the production base 54 for the production of the product 34. In addition, the materials 32 produced in the materials factory 52 are supplied (delivered) to the inventory center 56 as supplies. In addition, the product 34 produced using the materials 32 at the production base 54 is delivered to the sales store 64 and provided to consumers. In addition, the materials 32 stored in the inventory center 56 are delivered to the sales store 66 and provided to consumers as supplies.

[0051] Figure 2 It is a diagram showing the logistics when there is a shortage of materials. Due to reasons such as poor quality of the materials 32 in the materials factory 52, sometimes the materials 32 are not supplied from the materials factory 52. In this case, the materials 32 are insufficient. In such a case, it may not be possible to produce the product 34 at the production base 54. In the present embodiment, it is configured that when the materials 32 (deficient materials) are insufficient due to the stop of supply from the materials factory 52 as described above, as shown by the thick arrow, the materials 32 can be delivered from the inventory center 56 to the production base 54. Here, in Embodiment 1, the logistics warehouse that supplies materials to the market is used as the inventory center 56. By using the logistics warehouse as the inventory center, there is no need to separately set up an inventory center for supplying materials to the production base.

[0052] <Structure of the Material Supply System>

[0053] Next, the material supply system according to Embodiment 1 will be described.

[0054] Figure 3FIG. 0 is a diagram showing the hardware configuration of the material supply system according to Embodiment 1. Here, the material supply system 1 can be implemented by one or more information processing devices such as a computer. For example, the material supply system 1 can also be implemented by a cloud system. Additionally, the material supply system 1 can be implemented by multiple devices (e.g., servers). In this case, each of the multiple devices can have the Figure 3 hardware configuration shown.

[0055] As the main hardware configuration, the material supply system 1 includes a CPU (Central Processing Unit) 12, a ROM (Read Only Memory) 14, a RAM (Random Access Memory) 16, and an interface unit (IF; Interface) 18. The CPU 12, the ROM 14, the RAM 16, and the interface unit 18 are interconnected via a data bus or the like.

[0056] The CPU 12 functions as an arithmetic device (processing device or processor) for performing control processing, arithmetic processing, etc. The ROM 14 functions as a memory for storing control programs, arithmetic programs, etc. to be executed by the CPU 12. The RAM 16 functions as a memory for temporarily storing processing data, etc. The interface unit 18 inputs and outputs signals to and from the outside, either wired or wirelessly. Additionally, the interface unit 18 receives input operations of data performed by the user and performs processing for displaying information to the user. The interface unit 18 can have, for example, an input device such as a keyboard and an output device such as a display. Additionally, the interface unit 18 can also have a touch panel where the input device and the output device are integrated. Furthermore, the interface unit 18 can also have a microphone and a speaker. For example, the interface unit 18 can display information related to the delivery plan.

[0057] Figure 4 FIG. 12 is a functional block diagram showing the configuration of the material supply system 1 according to Embodiment 1. As components, the material supply system 1 includes an information storage unit 100, a logistics management unit 120, and a material supply control unit 130. The information storage unit 100 includes a product information storage unit 102, a production plan storage unit 104, a remaining amount information storage unit 106, an inventory information storage unit 108, a delivery information storage unit 110, and a movement information storage unit 112. The logistics management unit 120 includes an inventory management unit 122 and a delivery management unit 124. The material supply control unit 130 includes a stop notification receiving unit 132, a shortage material determination unit 134, an information acquisition unit 140, a production base determination unit 150, a shortage amount calculation unit 160, an inventory center determination unit 170, and a delivery plan unit 180.

[0058] In addition, each component of the above-described material supply system 1 is not limited to being physically implemented by a single device. For example, it can also be implemented by multiple devices through cloud computing or the like. That is, the material supply system 1 can also be physically composed of multiple devices. For example, the information storage unit 100 and the logistics management unit 120 can also be implemented by devices other than the material supply control unit 130, respectively.

[0059] In addition, these components can be implemented, for example, by the CPU 12 executing a program stored in the ROM 14. In addition, each component can also record the necessary program on an arbitrary non-volatile recording medium and install it as needed to be implemented. In addition, each structural element is not limited to being implemented by software as described above, and can also be implemented by some circuit elements or other hardware. In addition, each component can also be implemented using an integrated circuit that can be programmed by a user, such as an FPGA (field-programmable gate array) or a microcomputer. In this case, the integrated circuit can be used to implement the program composed of the above-described components. In addition, one or more of the above-described components can be physically implemented by separate hardware respectively.

[0060] The information storage unit 100 stores various information related to production and logistics. Here, the information storage unit 100 can store information regardless of whether the supply of materials is stopped. In addition, the information storage unit 100 can be implemented by a single database. Or, the information storage unit 100 can also be implemented by multiple databases. In this case, each component of the information storage unit 100 can be implemented by a mutually different database.

[0061] Moreover, each component of the information storage unit 100 can also be implemented by mutually different devices. For example, each component of the information storage unit 100 can also be implemented by a database or a server managed by a corresponding organization (department, etc.). For example, the product information storage unit 102 can be implemented by a database or a server managed by the design department. In addition, the production plan storage unit 104 and the remaining amount information storage unit 106 can be implemented by a database or a server managed by the production management department. In addition, the inventory information storage unit 108 can be implemented by a database or a server managed by the inventory management department or the after-sales service department. In addition, the distribution information storage unit 110 can be implemented by a database or a server managed by the distribution management department.

[0062] The product information storage unit 102 stores product information. The product information is information related to the products produced at each production site. The product information shows the types of materials (such as product numbers) that make up the product for each type of product. That is, the product information correlates the type of product with the types of materials that make up the product. The product information also shows the usage amounts of the materials that make up the corresponding product in the product. The usage amount is, for example, the number of each material used in the product. The product information can be, for example, drawing data representing the product and its components. Additionally, when the product is an automobile, the type of product can be the model or the vehicle name.

[0063] Figure 5 It is a diagram illustrating the product information stored in the product information storage unit 102 according to Embodiment 1. In Figure 5 the example, the product information shows product A and product B as the types of products. Figure 5 The exemplified product information shows the types of materials that make up product A and their usage amounts in product A, and the types of materials that make up product B and their usage amounts in product B.

[0064] In Figure 5 the example, product A is composed of at least material a, material b, and material c. Additionally, the usage amount of material a in product A is n_a. Additionally, the usage amount of material b in product A is n_b. Additionally, the usage amount of material c in product A is n_c. Additionally, product B is composed of at least material d, material e, and material f. Additionally, the usage amount of material d in product B is n_d. Additionally, the usage amount of material e in product B is n_e. Additionally, the usage amount of material f in product B is n_f.

[0065] Furthermore, in the product information, "product A" and "product B" can also represent the types of each product (such as the model, etc.). This is the same for other information. Additionally, for example, the usage amount n_a is the number of times material a is used in product A. The same applies to other usage amounts. Additionally, in the product information, "material a", "material b", "material c", "material d", "material e", and "material f" can also represent the product numbers (types) of each material. This is the same for other information. Additionally, a certain material can be used in multiple products. For example, material a can be used not only in product A but also in product B. Additionally, the product information shows in which product a material is used. Therefore, the product information can be said to be usage information as information related to the use of materials.

[0066] The production plan storage unit 104 ( Figure 4)Stores the production plan. The production plan shows, for each type of product, the production bases for manufacturing that product. That is, the production plan correlates the types of products with the production bases for manufacturing those products. The production plan also shows the planned production volumes of the corresponding products at each production base. The planned production volume indicates, for example, how many products are to be produced during a certain period. In the case where the product is an automobile, the planned production volume may be the number of units planned to be produced per month.

[0067] Figure 6 is a diagram illustrating the production plan stored in the production plan storage unit 104 according to Embodiment 1. In Figure 6 this example, the product plan shows product A and product B as types of products. The production plan shows the production bases for manufacturing product A and the planned production volumes at these production bases, and the production bases for manufacturing product B and the planned production volumes at these production bases.

[0068] In Figure 6 this example, product A is produced at production bases #F1 and #F2. The planned production volume of product A at production base #F1 is m_A1. The planned production volume of product A at production base #F2 is m_A2. In addition, product B is produced at production bases #F3 and #F4. The planned production volume of product B at production base #F3 is m_B3. The planned production volume of product B at production base #F4 is m_B4.

[0069] In addition, in the production plan, "production base #F1" may also represent the identification information of this production base. The same applies to other production bases and other information. In addition, the production plan shows at which production base a product is produced, and each product is composed of multiple materials. Therefore, the production plan represents the production plan of the products using materials at each of the multiple production bases.

[0070] The remaining quantity information storage unit 106 ( Figure 4 ) stores the remaining quantity information. The remaining quantity information represents the remaining quantity of each material at each of the multiple production bases. That is, the remaining quantity information correlates the production base, the material located at that production base, and the remaining quantity of that material. Here, the remaining quantity is the quantity of the material existing at each production base. In other words, the remaining quantity is the quantity (e.g., number) of the material that has not been used and remains at each production base. For example, the remaining quantity may be the quantity of the inventory of each material at the production base. Here, in Embodiment 1, the materials remaining at each production base are successively used as the products are produced.

[0071] Figure 7 is a diagram illustrating the remaining quantity information stored in the remaining quantity information storage unit 106 according to Embodiment 1. In Figure 7In the example, the surplus information shows the surplus of each material in production site #F1 and the surplus of each material in production site #F2. In Figure 7 the example, the surplus of material a in production site #F1 is r_a1. The surplus of material b in production site #F1 is r_b1. The surplus of material c in production site #F1 is r_c1. Additionally, in Figure 7 the example, the surplus of material a in production site #F2 is r_a2. The surplus of material b in production site #F2 is r_b2. The surplus of material c in production site #F2 is r_c2.

[0072] The inventory information storage unit 108 ( Figure 4 ) stores inventory information. The inventory information represents the inventory quantity of each material in each of a plurality of inventory centers. That is, the inventory information associates an inventory center, the material located in that inventory center, and the inventory quantity of that material. The inventory quantity is the quantity (e.g., number) of the material stored in each inventory center. Here, in Embodiment 1, the materials stored in each inventory center are appropriately distributed to the sales stores according to the demand as replenishment supplies.

[0073] Figure 8 is a diagram illustrating the inventory information stored by the inventory information storage unit 108 according to Embodiment 1. In Figure 8 it, the inventory information shows the inventory quantity of each material in inventory center #S1 and the inventory quantity of each material in inventory center #S2. In Figure 8 the example, the inventory quantity of material a in inventory center #S1 is R_a1. The inventory quantity of material b in inventory center #S1 is R_b1. The inventory quantity of material c in inventory center #S1 is R_c1. Additionally, in Figure 8 the example, the inventory quantity of material a in inventory center #S2 is R_a2. The inventory quantity of material b in inventory center #S2 is R_b2. The inventory quantity of material c in inventory center #S2 is R_c2.

[0074] The delivery information storage unit 110 ( Figure 4 ) stores delivery information. The delivery information is information related to the delivery plan for each of one or more transportation companies. The delivery information can be information provided by each transportation company.

[0075] Figure 9 is a diagram illustrating the delivery information stored by the delivery information storage unit 110 according to Embodiment 1. In Figure 9 the example, the delivery information shows at least the information related to transportation company A and transportation company B. In Figure 9In the example, the distribution information shows the number of vehicles in operation and the number of vehicles not in operation for transportation company A and transportation company B, respectively. Here, "in operation" means that the vehicle (such as a truck) used for distribution is not staying at the transportation company for the purpose of distribution. In addition, "in operation" can also include the state where the next distribution schedule has been determined and the vehicle is on standby at the transportation company. In addition, "not in operation" means the state where the distribution schedule has not been determined. In addition, "not in operation" can also be the state where the vehicle is only staying at the transportation company.

[0076] In addition, in Figure 9 the example, the distribution information shows the distribution route, time allocation, and deviation for transportation company A and transportation company B, respectively. The distribution route represents the existing distribution path contracted by the corresponding transportation company. In addition, "time allocation and deviation" shows the scheduled departure time and arrival time for each distribution, and the delay or advance status relative to them.

[0077] In addition, in Figure 9 the example, the distribution information shows the capacity of all vehicles and the occupancy rate of goods in the vehicles in operation for transportation company A and transportation company B, respectively. Here, "capacity" represents the amount of goods that the vehicle can load. The capacity can be, for example, the maximum loading capacity, or the maximum volume of the space that the vehicle can occupy, or both. In addition, the occupancy rate of goods is the ratio of the goods loaded on the vehicle to the capacity of the vehicle (loading capacity). The loading capacity can be the weight of the goods or the volume of the goods.

[0078] In addition, the distribution information can also show Figure 9 items other than those shown in

[0079] The movement information storage unit 112 ( Figure 4 ) stores movement information. The movement information is information required to obtain the time required for movement between each of a plurality of production bases and each of a plurality of inventory centers. The movement information can include the location information of each production base and the location information of each inventory center. The location information can represent the address of the production base and the inventory center, or it can represent the latitude and longitude. In addition, if the location information of the starting point and the destination is known, the movement time can be known based on the shortest distance between them and the vehicle speed. Therefore, it can be said that the location information is information required to obtain the time required for movement between each of a plurality of production bases and each of a plurality of inventory centers. In addition, the movement information can also include information representing the shortest distance between each production base and each inventory center.

[0080] In addition, the movement information can also represent the travel time of the vehicle between the inventory center and the production base. The travel time is the time required for the vehicle to move between the inventory center and the production base as estimated. The travel time can be calculated, for example, based on the average speed of the vehicle and the shortest distance between the inventory center and the production base. Additionally, the travel time can also be calculated based on the data obtained by the vehicle actually traveling between the inventory center and the production base. For example, the travel time can be calculated using an algorithm that calculates the required time by specifying the starting point and the destination point in the map information.

[0081] Figure 10 FIG. is an example showing the movement information stored in the movement information storage unit 112 according to Embodiment 1. In Figure 10 this example, the movement information shows information related to production bases #F1 and #F2, and inventory centers #S1 and #S2. In Figure 10 this example, the movement information includes the location information of production base #F1, production base #F2, inventory center #S1, and inventory center #S2. In Figure 10 this example, the location information of production base #F1 is P_F1. The location information of production base #F2 is P_F2. The location information of inventory center #S1 is P_S1. The location information of inventory center #S1 is P_S2. Additionally, the location information of the production base can also be included in the production plan. Also, the location information of the inventory center can be included in the inventory information.

[0082] In addition, in Figure 10 this example, it includes the travel time of the vehicle between each inventory center and each production base. In Figure 10 this example, the travel time between inventory center #S1 and production base #F1 is T11. Additionally, the travel time between inventory center #S1 and production base #F2 is T12. Additionally, the travel time between inventory center #S2 and production base #F1 is T21. Additionally, the travel time between inventory center #S2 and production base #F2 is T22.

[0083] The logistics management unit 120 ( Figure 4 ) manages the plans and information related to logistics. Here, the logistics management unit 120 can execute processing regardless of whether the supply of materials has stopped. In addition, the logistics management unit 120 can be implemented by one device. Or, the logistics management unit 120 can also be implemented by multiple devices. In this case, each component of the logistics management unit 120 can be implemented by different devices.

[0084] The inventory management department 122 manages the inventory center. The inventory management department 122 manages inventory information. In addition, when the inventory information storage unit 108 is implemented by a device other than the other components of the information storage unit 100, the inventory management department 122 can be implemented by the device that implements the inventory information storage unit 108 or the device that controls the device. The inventory management department 122 uses the inventory information to manage the inventory levels of various materials in each inventory center. The inventory management department 122, for example, manages the order reception (demand) and supply of materials (supplies) stored in the inventory center.

[0085] For example, when there is an order reception for a certain material (supply) in a certain inventory center, the inventory management department 122 reduces the inventory level of the material corresponding to the inventory center in the inventory information according to the order reception quantity. For example, in Figure 8 the example, when there is one order reception for material a in inventory center #S1, the inventory management department 122 reduces the quantity of R_a1 by one. In addition, as described later, when supplying insufficient materials from a certain inventory center to a certain production base, the inventory management department 122 reduces the inventory level of the insufficient materials corresponding to the inventory center in the inventory information according to the supplied quantity.

[0086] The distribution management department 124 manages the normal distribution plan. The distribution management department 124 uses the distribution information to manage the distribution plan. In addition, when the distribution information storage unit 110 is implemented by a device other than the other components of the information storage unit 100, the distribution management department 124 can be implemented by the device that implements the distribution information storage unit 110 or the device that controls the device.

[0087] In the case where Figure 2 as exemplified, the supply of materials from the material factory stops, the material supply control department 130 performs control related to the supply of the insufficient materials, which are the materials with supply stopped, from the inventory center. In addition, the material supply control department 130 can be implemented by one device. Or, the material supply control department 130 can also be implemented by multiple devices. In this case, each component of the material supply control department 130 can be implemented by mutually different devices.

[0088] The stop notice receiving department 132 receives the stop notice from the supplier. The stop notice receiving department 132 receives the stop notice through the interface department 18. In Figure 2 the example, the stop notice receiving department 132 receives the stop notice from the device (server or terminal) that manages the supplier of the material factory 52. Here, the stop notice can at least show the product number of the insufficient materials and the expected time for the recovery of the supply of the insufficient materials. For example, in Figure 5In examples such as this, when the supply of Material A stops, a stop notice is received from the supplier of Material A. Additionally, the stop notice shows the product number of Material A and the expected time for the resumption of the supply of Material A.

[0089] The shortage material determination unit 134 determines the shortage material. Specifically, the shortage material determination unit 134 uses the received stop notice to determine the shortage material. More specifically, the shortage material determination unit 134 extracts the product number of the shortage material from the stop notice. Additionally, the product number of the shortage material determined by the shortage material determination unit 134 can be stored in the database implemented by the ROM 14. Similarly, the expected time for the resumption of the supply of the shortage material can also be stored in the database. The information stored in the database can be managed by the material supply control unit 130.

[0090] The information acquisition unit 140 uses the information stored in the information storage unit 100 to acquire information related to the shortage material (shortage material information). Specifically, the information acquisition unit 140 acquires usage information related to the use of the shortage material. More specifically, the information acquisition unit 140 uses the product information stored in the product information storage unit 102 to acquire product information (usage information) related to the product using the shortage material. Thereby, the information acquisition unit 140 acquires the types of products using the shortage material. Additionally, the information acquisition unit 140 acquires the usage amount of the shortage material for each product among the products using the shortage material.

[0091] For example, in Figure 5 the example, when the shortage material is Material A, the information acquisition unit 140 acquires product information related to the product using Material A. Thereby, the information acquisition unit 140 acquires the type of product "Product A" that uses Material A (the shortage material). Additionally, the information acquisition unit 140 acquires the usage amount "n_a" of Material A for each product of Product A that uses Material A (the shortage material).

[0092] Furthermore, the information acquisition unit 140 uses the production plan stored in the production plan storage unit 104 to acquire the production plan of the product using the shortage material. Thereby, the information acquisition unit 140 acquires the identification information of the production site related to the product using the shortage material. Additionally, the information acquisition unit 140 acquires the planned production volume of the product using the shortage material at this production site.

[0093] For example, in Figure 5 and Figure 6In the example where the shortage material is material a, the information acquisition unit 140 acquires the production plan related to product A using material a. Thus, the information acquisition unit 140 acquires the identification information of production bases #F1 and #F2 that produce product A using material a. In addition, the information acquisition unit 140 acquires the planned production volume "m_A1" of product A for production base #F1 that produces product A. Similarly, the information acquisition unit 140 acquires "m_A2" of product A for production base #F2 that produces product A.

[0094] In addition, the information acquisition unit 140 uses the remaining amount information stored in the remaining amount information storage unit 106 to acquire the remaining amount information related to the shortage material in each production base that produces the product using the shortage material. Thus, the information acquisition unit 140 acquires the remaining amount of the shortage material in each production base. For example, in Figures 5 to 7 the example where the shortage material is material a, the information acquisition unit 140 acquires the remaining amount "r_a1" of material a for production base #F1 that produces product A using material a (the shortage material). Similarly, the information acquisition unit 140 acquires the remaining amount "r_a2" of material a for production base #F2 that produces product A using material a (the shortage material).

[0095] In addition, the information acquisition unit 140 uses the inventory information stored in the inventory information storage unit 108 to acquire the inventory information related to the shortage material in each inventory center that stores the shortage material. Thus, the information acquisition unit 140 acquires the inventory quantity of the shortage material in each inventory center. For example, in Figure 8 the example where the shortage material is material a, the information acquisition unit 140 acquires the remaining amount "R_a1" of material a for inventory center #S1 that stores material a (the shortage material). Similarly, the information acquisition unit 140 acquires the remaining amount "R_a2" of material a for inventory center #S2 that stores material a (the shortage material).

[0096] In addition, the information acquisition unit 140 uses the movement information stored in the movement information storage unit 112 to acquire the movement information related to the movement time between each inventory center that stores the shortage material and each production base that uses the shortage material. For example, in Figures 5 to 8 and Figure 10In the example where the shortage material is material a, the information acquisition unit 140 acquires movement information related to each of inventory centers #S1 and #S2 storing material a (the shortage material) and production sites #F1 and #F2 using material a. For example, the information acquisition unit 140 acquires the location information "P_S1" and "P_S2" of inventory centers #S1 and #S2 respectively, and the location information "P_F1" and "P_F2" of production sites #F1 and #F2 respectively. Alternatively, the information acquisition unit 140 acquires the movement times "T11", "T12", "T21", and "T22" between inventory centers #S1 and #S2 and production sites #F1 and #F2 respectively.

[0097] In addition, as described above, each component of the information storage unit 100 may also be implemented by different devices. In this case, the above functions of the information acquisition unit 140 may be implemented by the devices implementing each component of the information storage unit 100 or the devices controlling these devices. That is, the information acquisition unit 140 may also be implemented by multiple devices. For example, the function of the information acquisition unit 140 for acquiring product information may be implemented by the device implementing the product information storage unit 102 or the like. In addition, the function of the information acquisition unit 140 for acquiring the production plan may be implemented by the device implementing the production plan storage unit 104 or the like. In addition, the function of the information acquisition unit 140 for acquiring the remaining quantity information may be implemented by the device implementing the remaining quantity information storage unit 106 or the like. In addition, the function of the information acquisition unit 140 for acquiring the inventory information may be implemented by the device implementing the inventory information storage unit 108 or the like.

[0098] The production site determination unit 150 determines the production site that uses the shortage material. Specifically, the production site determination unit 150 uses the product information acquired by the information acquisition unit 140 to determine the type of product that uses the shortage material. And the production site determination unit 150 uses the production plan acquired by the information acquisition unit 140 to determine the production sites #F1 and #F2 that produce the product using the shortage material as the production sites that use the shortage material.

[0099] For example, in Figure 5 and Figure 6 the example, when the shortage material is material a, the production site determination unit 150 uses the product information acquired by the information acquisition unit 140 to determine the type of product "Product A" that uses material a (the shortage material). Then, the production site determination unit 150 uses the production plan acquired by the information acquisition unit 140 to determine the production sites #F1 and #F2 that produce Product A using material a (the shortage material).

[0100] In addition, the production site determination unit 150 may also generate material usage information that correlates the shortage materials with the production sites that use such shortage materials. Specifically, the production site determination unit 150 may generate the material usage information by using the product information related to the product that uses the shortage materials and the production plan for producing the product that uses the shortage materials.

[0101] Alternatively, the production site determination unit 150 may also generate the material usage information by using the surplus information. Specifically, the production site determination unit 150 may generate the material usage information by extracting (retrieving) the identification information of the production sites corresponding to the shortage materials from the surplus information. For example, in Figure 7 the example, when material a is a shortage material, the production site determination unit 150 may generate the material usage information by extracting the identification information of production site #F1 and production site #F2 corresponding to material a from the surplus information.

[0102] Figure 11 FIG. is a diagram illustrating the material usage information according to Embodiment 1. Figure 11 The material usage information related to material a is shown. In Figure 11 the exemplified material usage information, material a corresponds to production site #F1 and production site #F2. In addition, the material usage information may also correspond the shortage amounts of the shortage materials calculated by the following processing for each production site.

[0103] In addition, the material usage information may be pre-stored in the information storage unit 100 for each material. In this case, the information acquisition unit 140 may acquire the material usage information corresponding to the shortage materials from the information storage unit 100. Alternatively, the information acquisition unit 140 may also generate the material usage information related to the shortage materials in the same manner as the production site determination unit 150. In these cases, the production site determination unit 150 may use the material usage information related to the shortage materials acquired by the information acquisition unit 140 to determine the production sites related to the shortage materials.

[0104] The shortage amount calculation unit 160 calculates the shortage amounts of the shortage materials for each production site that uses the shortage materials by using the usage information, the production plan, and the surplus information. Preferably, the shortage amount calculation unit 160 calculates the shortage amounts of the shortage materials within a specified period for each production site. Specifically, the shortage amount calculation unit 160 calculates the shortage amounts of the shortage materials within the period Tr until the expected time of recovery for each production site by using the usage amounts indicated in the product information, the surpluses indicated in the surplus information, and the planned production amounts indicated in the production plan. In addition, the shortage amount calculation unit 160 may also calculate the shortage amounts by using the material usage information.

[0105] More specifically, the shortage amount calculation unit 160 performs the following processing for each production site. That is, the shortage amount calculation unit 160 calculates the amount M of the product that should be produced during the period Tr until the expected recovery time by multiplying the planned production volume m of the product using the shortage material by Tr. In addition, the shortage amount calculation unit 160 calculates the usage amount N of the shortage material used in this production site during the period Tr until the expected recovery time by multiplying the amount M of the product by the usage amount n of the shortage material used in this product. In addition, when multiple products using the shortage material are produced in this production site, the shortage amount calculation unit 160 calculates the usage amount N by adding the products obtained by multiplying M by n for each of the multiple products. In addition, the shortage amount calculation unit 160 calculates the shortage amount K for each production site by subtracting the surplus amount r from the usage amount N of the shortage material.

[0106] For example, in Figure 5 examples such as, when the shortage material is material a, the shortage amount calculation unit 160 performs the following processing for production site #F1. The shortage amount calculation unit 160 calculates the amount M1 of product A that should be produced during the period Tr by multiplying the planned production volume m_A1 of product A in production site #F1 that uses material a by Tr. Here, M1 = Cons × m_A1 × Tr. Cons is a constant used to make the time units between m_A1 and Tr consistent. In addition, the shortage amount calculation unit 160 calculates the usage amount N1 of material a used in production site #F1 during the period Tr until the expected recovery time by multiplying the amount M1 of product A by the usage amount n_a of material a used in product A. Here, N1 = M1 × n_a. In addition, the shortage amount calculation unit 160 calculates the shortage amount K1 of material a in production site #F1 by subtracting the surplus amount r_a1 from the usage amount N1 of material a. Here, K1 = N1 - r_a1. In addition, if K1 ≤ 0, since the supply of material a recovers before the surplus amount r_a1 is exhausted, material a will not be in shortage in production site #F1.

[0107] In addition, the shortage calculation unit 160 performs the following processing for production site #F2. The shortage calculation unit 160 calculates the amount M2 of product A to be produced during the period Tr by multiplying the planned production volume m_A2 of product A at production site #F2 using material a by Tr. Here, M2 = Cons × m_A2 × Tr. In addition, the shortage calculation unit 160 calculates the usage amount N2 of material a used at production site #F2 during the period Tr until the expected recovery time by multiplying the amount M2 of product A by the usage amount n_a of material a used in product A. Here, N2 = M2 × n_a. In addition, the shortage calculation unit 160 calculates the shortage amount K2 of material a at production site #F2 by subtracting the surplus amount r_a2 from the usage amount N2 of material a. Here, K2 = N2 - r_a2. In addition, if K2 ≤ 0, since the supply of material a recovers before the surplus amount r_a2 is exhausted, material a will not be in shortage at production site #F2.

[0108] The inventory center determination unit 170 determines the inventory center that supplies the shortage materials to each production site in the shortest way using the inventory information, movement information, and shortage amount. Specifically, the inventory center determination unit 170 uses the inventory information to determine the inventory centers where there is inventory of the shortage materials. Here, the inventory center determination unit 170 can also use the inventory information to determine the inventory centers that store the shortage materials in an amount greater than the shortage amount. That is, the inventory center determination unit 170 can determine the inventory centers where the inventory quantity R of the shortage materials is greater than the shortage amount K of the shortage materials. And, when there are multiple determined inventory centers, the inventory center determination unit 170 uses the movement information to determine the inventory center that can distribute the shortage materials to each production site in the shortest (shortest time) way. In this way, the inventory center determination unit 170 determines the inventory center that supplies the shortage materials to each production site.

[0109] For example, in Figure 5 such examples, when the shortage material is material a, the inventory center determination unit 170 uses Figure 8 the exemplified inventory information and determines that material a is stored in inventory center #S1 and inventory center #S2. And the inventory center determination unit 170 can perform the following processing for production site #F1 and production site #F2 respectively. In addition, in the following description, the processing for production site #F1 is described, but the same applies to production site #F2. That is, in the following description, only K1 needs to be replaced with K2.

[0110] The inventory center determination unit 170 determines for each of the inventory centers #S1 and #S2 whether it is possible to supply the insufficient amount K1 of material a to the production base #F1. That is, the inventory center determination unit 170 determines whether R_a1≥K1 and whether R_a2≥K1. The inventory center determination unit 170 can, when it is determined that only one of the inventory centers #S1 and #S2 can supply the insufficient amount K1 of material a to the production base #F1, determine that one inventory center as the inventory center that supplies material a to the production base #F1. For example, the inventory center determination unit 170 can, when R_a1≥K1 and R_a2<K1, determine the inventory center #S1 as the inventory center that supplies material a to the production base #F1.

[0111] In addition, in the above example, when the same inventory center is determined for each production base, the inventory center determination unit 170 can determine whether the inventory of the shortage material in the determined inventory center is equal to or greater than the sum of the shortages of each production base. For example, when the inventory center #S1 is determined for each of the production bases #F1 and #F2, the inventory center determination unit 170 can determine whether R_a1≥K1+K2. When R_a1≥K1+K2, the inventory center determination unit 170 can determine to supply material a from the inventory center #S1 to the production bases #F1 and #F2.

[0112] On the other hand, when R_a1<K1+K2, the inventory center determination unit 170 can perform the following alternative processing. For example, the inventory center determination unit 170 can determine to supply an amount of R_a1 / 2 of material a from the inventory center #S1 to each of the production bases #F1 and #F2. That is, the inventory center determination unit 170 can determine to equally supply all the inventory of the material (shortage material) in the determined inventory center to each production base. Or, the inventory center determination unit 170 can also determine to supply an amount of R_a1×K1 / (K1+K2) of material a from the inventory center #S1 to the production base #F1 and an amount of R_a1×K2 / (K1+K2) of material a to the production base #F2. That is, the inventory center determination unit 170 can determine to supply all the inventory of the material (shortage material) in the determined inventory center to each production base according to the ratio of the shortages in each production base.

[0113] Alternatively, the inventory center determination unit 170 may also determine to supply all the inventory of materials (deficient materials) in the determined inventory center to each production base in such a way that more materials are preferentially supplied to a specific production base among each production base. For example, the inventory center determination unit 170 may determine to supply all the inventory of materials (deficient materials) in the determined inventory center to each production base in such a way that more materials are supplied to the production base with more importance in production (the production base with a higher priority) among each production base.

[0114] Alternatively, for example, the inventory center determination unit 170 may also determine to supply the deficient quantity of the production base in the determined inventory center to the production base with more importance in production among each production base, and supply the remaining quantity to another production base. In this case, the inventory center determination unit 170 may determine to supply the quantity lacking for the deficient quantity of another production base to another production base from the inventory center that is not determined but stores the deficient materials. Conversely, the inventory center determination unit 170 may also supply all the inventory of the deficient materials to another production base from the inventory center that is not determined but stores the deficient materials, and supply the quantity lacking for the deficient quantity from other inventory centers including the determined inventory center.

[0115] For example, in Figure 8 the example of, it is assumed that R_a2 < K1, R_a2 < K2, K1 < R_a1, K2 < R_a1 and R_a1 < K1 + K2, and production base #F1 is more important (has a higher priority) than production base #F2. In this case, the inventory center determination unit 170 determines the inventory center that can supply material a (deficient material) to production base #F1 and production base #F2 as inventory center #S1. And the inventory center determination unit 170 may determine to supply the deficient quantity K1 of material a in the inventory of material a in inventory center #S1 to production base #F1.

[0116] And the inventory center determination unit 170 may determine to supply the remaining inventory R_a1 - K1 of material a in inventory center #S1 to production base #F2. And the inventory center determination unit 170 may determine to supply the quantity lacking for the deficient quantity K2, which is K2 - (R_a1 - K1), to production base #F2 from the inventory R_a2 in inventory center #S2. Alternatively, the inventory center determination unit 170 may also determine to supply the inventory R_a2 of material a in inventory center #S2 to production base #F2. And the inventory center determination unit 170 may determine to supply the quantity lacking for the deficient quantity K2, which is K2 - R_a2, to production base #F2 from the remaining inventory R_a1 - K1 in inventory center #S1.

[0117] The Distribution Planning Department 180 makes a distribution plan for supplying shortage materials from the identified inventory centers to each production site. Specifically, the Distribution Planning Department 180 interrupts the normal distribution plan related to other materials different from the shortage materials and makes a distribution plan for the shortage materials. In addition, the normal distribution plan can be carried out regardless of whether the supply of materials is stopped. The specific processing of the Distribution Planning Department 180 will be described using the flowchart described later.

[0118] <Material Supply Method>

[0119] Figures 12 to 15 It is a flowchart showing the material supply method executed by the material supply system 1 according to Embodiment 1. Figures 12 to 15 The processing of is mainly executed by the Material Supply Control Department 130. In addition, Figure 12 and Figure 13 The processing of is for determining the inventory center that supplies shortage materials to the production site. On the other hand, Figure 14 and Figure 15 The processing of is for making a distribution plan for distributing shortage materials from the inventory center to the production site.

[0120] For Figure 12 and Figure 13 The processing of will be described. The Stop Notification Receiving Department 132 receives a stop notification from the supplier (step S102). As described above, the Shortage Material Determination Department 134 uses the received stop notification to determine the shortage materials (step S104). As described above, the Information Acquisition Department 140 uses the information stored in the Information Storage Department 100 to acquire shortage material information related to the shortage materials determined in the processing of S104 (step S106).

[0121] As described above, the Production Site Determination Department 150 uses the shortage material information obtained in the processing of S106 to determine the production sites that use the shortage materials (step S108). As described above, the Shortage Quantity Calculation Department 160 calculates the shortage quantity of the shortage materials for each production site that uses the shortage materials (step S110). The Inventory Center Determination Department 170 determines the inventory centers that can supply the shortage materials to each production site (step S112). Specifically, the Inventory Center Determination Department 170 determines the inventory centers that store more than the shortage quantity of the shortage materials. In addition, at this time point, the inventory centers that actually supply the shortage materials to each production site have not been determined.

[0122] When there is only one production site with insufficient materials (Yes in step S114), it is determined whether there is only one inventory center that can supply the insufficient materials (step S116). Then, when there is only one inventory center that can supply the insufficient materials (Yes in S116), the inventory center determination unit 170 determines this one inventory center as the inventory center that supplies the insufficient materials to the one production site with insufficient materials (step S118).

[0123] Then, the inventory center determination unit 170 calculates the shortest path from this one inventory center to the one production site. Here, the so-called "shortest path" is a path that can deliver the insufficient materials from the inventory center to the production site in the shortest time, taking into account the distance from the inventory center to the production site, the congestion state of the road, the availability of vehicle-priority roads such as highways, etc. For example, the inventory center determination unit 170 may use the path used when calculating the travel time from the inventory center shown in the movement information to the production site as the shortest path. Or, the inventory center determination unit 170 may also calculate the shortest path from the position of the inventory center shown in the movement information to the position of the production site shown in the movement information. In addition, the shortest path from one position to another can be calculated using, for example, the A* algorithm or Dijkstra's method. These methods of calculating the shortest path are the same in other processes.

[0124] On the other hand, when there are multiple inventory centers that can supply the insufficient materials (No in step S116), the inventory center determination unit 170 determines the inventory center that can be delivered to the production site in the shortest time (step S120). Specifically, the inventory center determination unit 170 calculates the shortest path from each of the determined multiple inventory centers to the one production site with insufficient materials. Then, the inventory center determination unit 170 determines the inventory center with the shortest travel time (delivery time) among the calculated shortest paths as the inventory center that supplies the insufficient materials to the one production site with insufficient materials.

[0125] On the other hand, when there are multiple production sites with insufficient materials (No in S114), it is determined whether there is only one inventory center that can supply the insufficient materials (step S122). Then, when there is only one inventory center that can supply the insufficient materials (Yes in S122), the inventory center determination unit 170 determines this one inventory center as the inventory center that supplies the insufficient materials to each of the multiple production sites (step S124). Then, the inventory center determination unit 170 calculates the shortest path from the one inventory center for each of the multiple production sites. In addition, since the insufficient materials will be supplied from the one inventory center to multiple production sites, there is a possibility that the inventory of this one inventory center will be insufficient. In this case, the inventory center determination unit 170 can perform the substitution process as described above.

[0126] On the other hand, when there are multiple inventory centers that can supply insufficient materials (No in S122), the inventory center determination unit 170 determines, for each of the multiple production sites, the inventory center that can be delivered to the production site in the shortest time (step S126). Specifically, the inventory center determination unit 170 calculates, for each of the multiple production sites, the shortest path from each of the determined multiple inventory centers. Then, for each of the multiple production sites, the inventory center determination unit 170 determines, as the inventory center for supplying the insufficient materials, the inventory center with the shortest moving time (delivery time) among the calculated shortest paths. In addition, when the same inventory center is determined for two or more of the multiple production sites, since the insufficient materials are supplied from one inventory center to multiple production sites, there is a possibility that the inventory of the one inventory center will be insufficient. In this case, the inventory center determination unit 170 can perform the substitution process in the case where the same inventory center is determined for each production site as described above.

[0127] In addition, when there are multiple production sites for the underused materials and multiple inventory centers for storing the underused materials, the inventory center determination unit 170 can also determine the inventory centers for supplying the underused materials to the multiple production sites respectively by considering the shortage amount in each production site and the inventory amount in each inventory center. For example, in Figure 5 In an example such as, it is assumed that the insufficient material is material a. In this case, the production sites using material a as the insufficient material are production site #F1 and production site #F2, and the inventory centers storing material a are inventory center #S1 and inventory center #S2. In addition, let the shortage amount of material a in production site #F1 be K1, and the shortage amount of material a in production site #F2 be K2. In addition, the inventory amount of material a in inventory center #S1 is R_a1, and the inventory amount of material a in inventory center #S2 is R_a2.

[0128] In this case, for example, it is assumed that R_a1 > K1 > R_a2 > K2. And it is assumed that the inventory center determined to be able to deliver material a to production site #F1 in the shortest time is inventory center #S2, and the inventory center determined to be able to deliver material a to production site #F2 in the shortest time is inventory center #S1. In this case, the inventory center determination unit 170 determines that inventory center #S1 supplies material a in the shortage amount K2 of production site #F2 to production site #F2.

[0129] On the other hand, in inventory center #S2, only material a with an inventory quantity less than the shortage quantity K1 in production site #F1 is stored. Therefore, the inventory center determination unit 170 determines that all of the inventory quantity R_a2 of material a in inventory center #S2 is supplied to production site #F1 from inventory center #S2. And the inventory center determination unit 170 can perform the processing of S112 to S126 again for the quantity K1 - R_a2 that is still lacking in production site #F1. In this case, the inventory quantity of inventory center #S1 is set to R_a1 - K2, and the inventory quantity of inventory center #S2 is set to 0. And the inventory center determination unit 170 can determine that material a with a quantity of K1 - R_a2 is supplied to production site #F1 from inventory center #S1.

[0130] That is, when the quantity of shortage materials that can be supplied from the determined inventory center is less than the shortage quantity in the production site as the supply target, the inventory center determination unit 170 can further determine an inventory center other than the determined inventory center that supplies the shortage quantity of the shortage materials lacking for supplying this shortage quantity. Thereby, the quantity that can be supplied shortest can be supplied from the inventory center to the production site shortest, and the lacking quantity can be supplied from other inventory centers. Thereby, the shortage materials of the minimum quantity can be supplied shortest. Thereby, the influence on each production site can be reliably reduced.

[0131] As described above, the material supply system 1 according to Embodiment 1 is configured to calculate the shortage quantity of shortage materials for each of a plurality of production sites by using usage information, production plans, and margin information when the supply of materials used in the plurality of production sites stops. In addition, the material supply system 1 according to Embodiment 1 is configured to determine the inventory center that supplies the shortage materials to each of the plurality of production sites shortest by using inventory information, movement information, and the shortage quantity. Thereby, the shortage materials of the quantity required by each of the plurality of production sites can be supplied from the inventory center to each production site shortest. Therefore, the material supply system 1 according to Embodiment 1 can reduce the influence on each production site even when the supply of materials used in each of the plurality of production sites stops.

[0132] In addition, the material supply system 1 according to Embodiment 1 is configured to calculate the shortage quantity, that is, the quantity by which the shortage materials are lacking in each of the plurality of production sites during a specified period (the period until the expected recovery time). By determining the inventory center by using the shortage quantity calculated in this way, the shortage materials of the quantity lacking during the specified period can be appropriately supplied to each production site.

[0133] Next, for Figure 14 and Figure 15 an explanation will be given. Figure 14 and Figure 15 are used to perform as Figure 2Processing of the distribution plan from the inventory center to the production base as indicated by the thick arrow. In the following description, an example of determining to supply material a as a shortage material from inventory center #S1 to production base #F1 is appropriately used. Additionally, this processing can be performed independently for each production base.

[0134] The distribution planning department 180 determines the transportation company that delivers from the material factory to the inventory center determined by the inventory center determination department 170 (step S152). Specifically, the distribution planning department 180 uses the distribution information stored in the distribution information storage unit 110 to determine the transportation company that delivers to the determined inventory center under normal circumstances. For example, the distribution planning department 180 determines the transportation company that delivers to inventory center #S1, which is determined to supply the shortage material, based on the "distribution route" shown in the distribution information. Additionally, the transportation company that delivers from the material factory to the inventory center does not need to be the transportation company that delivers the material corresponding to the shortage material under normal circumstances. Therefore, the "material factory" in this distribution does not need to be the factory that produces the shortage material and can be any factory.

[0135] The distribution planning department 180 determines whether there are non-operating vehicles in the transportation company determined in the process of S152 (step S154). Specifically, the distribution planning department 180 uses the distribution information related to the determined transportation company to determine whether there are non-operating vehicles that can handle emergencies. For example, when the transportation company B is determined in the process of S152, the distribution planning department 180 determines whether the "number of non-operating vehicles" shown in the distribution information related to the transportation company B is not zero.

[0136] If there are non-operating vehicles (Yes in S154), the distribution planning department 180 performs processing for entrusting the transportation company determined in S152 to distribute the shortage materials from the inventory center to the production base (step S156). Specifically, the distribution planning department 180 performs processing for entrusting the determined transportation company to distribute the shortage materials from the determined inventory center to the production base that uses the shortage materials. For example, when the transportation company B is determined, the distribution planning department 180 entrusts the transportation company B to distribute material a as a shortage material from inventory center #S1 to production base #F1. Additionally, the distribution planning department 180 can also send information indicating the distribution entrustment to the terminal of the determined transportation company. For example, the distribution planning department 180 can send an email indicating the distribution entrustment to the terminal of the transportation company. The method of distribution entrustment is the same in the subsequent processing.

[0137] On the other hand, in the absence of a non-operating vehicle (No in S154), the distribution planning department 180 determines whether it is possible to interrupt the normal distribution plan for distributing materials other than the shortage materials (other materials) from the materials factory to the production site using the shortage materials (step S160). That is, the distribution planning department 180 determines whether it is possible to interrupt the normal distribution plan by the plan for distributing the shortage materials from the identified inventory center. In addition, this normal distribution plan may be a regular operation shift. In addition, this normal distribution plan corresponds to Figure 1 the logistics of other materials shown by the solid arrow from the materials factory 52 to the production site 54 in

[0138] Figure 16 It is a diagram for explaining the interruption of the normal distribution plan for distributing other materials from the materials factory to the production site using the shortage materials. In Figure 16 it, the materials factory 52 is a factory that produces other materials 32b. In addition, the inventory center 56 is an inventory center that stores the shortage materials 32a. In addition, the production site 54 is a factory that produces products using the shortage materials 32a, etc. That is, the production site 54 is a factory that uses the shortage materials 32a, etc.

[0139] In this case, by interruption is meant that when distributing other materials 32b from the materials factory 52 to the production site 54 during the regular shift, the vehicle loaded with other materials 32b is diverted to the inventory center 56 midway. That is, when distributing other materials 32b from the materials factory 52 to the production site 54, as shown by arrow A, the vehicle loaded with other materials 32b is diverted to the inventory center 56 before being delivered to the production site 54. Then, the shortage materials 32a are loaded onto this vehicle at the inventory center 56, and as shown by arrow B, the shortage materials 32a and other materials 32b are delivered to the production site 54. The distribution planning department 180 determines whether such an interruption is possible.

[0140] Specifically, the distribution planning department 180 determines whether the free capacity of the vehicle for distributing other materials is equal to or greater than the amount (occupation amount) occupied by the shortage materials in the vehicle during distribution. Here, the distribution planning department 180 uses the distribution information related to the corresponding vehicle to calculate the free capacity. Specifically, the distribution planning department 180 calculates the free capacity of the vehicle by calculating "vehicle capacity" × (1 - "cargo occupancy rate"). In addition, the distribution planning department 180 can calculate the occupation amount of the shortage materials by multiplying the occupation amount (volume, weight, etc.) of each shortage material by the quantity of the shortage materials (corresponding to the shortage amount). Then, when the free capacity of the vehicle for distributing other materials is equal to or greater than the occupation amount of the shortage materials, the distribution planning department 180 determines that the normal distribution plan for distributing other materials from the material factory to the production base can be interrupted. On the other hand, when the free capacity of the vehicle for distributing other materials is not equal to or greater than the occupation amount of the shortage materials, the distribution planning department 180 determines that the normal distribution plan for distributing other materials from the material factory to the production base cannot be interrupted.

[0141] When it is determined that the normal distribution plan for distributing other materials from the material factory to the production base can be interrupted (Yes in S160), the distribution planning department 180, as Figure 16 illustrated, plans to make the vehicle take a detour to the inventory center during the normal distribution of other materials from the material factory to the production base (step S162). At this time, through the following processing, the impact of the delay in the distribution of other materials on production is suppressed as much as possible.

[0142] The distribution planning department 180 calculates the delay time caused by the detour (step S164). Specifically, the distribution planning department 180 calculates the delay time by subtracting "the normal distribution time from the material factory to the production base" from "the time required from the material factory via the inventory center to the production base". In addition, regarding the calculation method of "the time required from the material factory via the inventory center to the production base", the time from the material factory to the inventory center can be calculated by calculating the shortest path from the material factory to the inventory center. In addition, the time required to load the shortage materials at the inventory center can be calculated according to the amount of the shortage materials, etc. In addition, the time from the inventory center to the production base can use the time calculated during the determination process of the inventory center by the inventory center determination department 170.

[0143] The Distribution Planning Department 180 determines whether the delay caused by the detour affects the production of products using other materials (step S166). Specifically, before the vehicle loaded with other materials and shortage materials arrives at the production site, when all the remaining other materials at the production site have been used, the Distribution Planning Department 180 determines that the delay caused by the detour affects the production of products using other materials. More specifically, the Distribution Planning Department 180 determines whether the product of the "remaining amount of other materials at the production site" and the "cycle time of each other material" is greater than or equal to the delay time. In other words, the Distribution Planning Department 180 determines whether it is "remaining amount of other materials at the production site" × "cycle time of each other material" ≥ "delay time". When the product of the "remaining amount of other materials at the production site" and the "cycle time of each other material" is greater than or equal to the delay time, the Distribution Planning Department 180 determines that the delay caused by the detour does not affect the production of products using other materials.

[0144] In addition, the Distribution Planning Department 180 can obtain the "remaining amount of other materials at the production site" by extracting the remaining amount related to other materials from the remaining amount information. In addition, the Distribution Planning Department 180 can calculate the "cycle time of each other material" using the usage amount of other materials in the product information related to the product using other materials and the planned production volume in the production plan of the product. For example, the Distribution Planning Department 180 can calculate the "cycle time of each other material" by dividing the tact time obtained by taking the reciprocal of the planned production volume of the product by the usage amount of other materials in the product. Alternatively, the cycle time of each material can be stored in the Information Storage Department 100 in advance for each product and each production site. In this case, the Distribution Planning Department 180 can extract the cycle time stored in advance in the Information Storage Department 100. In addition, the "cycle time of each other material" can vary according to each product using other materials. Therefore, when other materials are used for multiple products, the Distribution Planning Department 180 uses the shortest cycle time.

[0145] In the case where it is determined that the delay caused by the detour does not affect the production of products using other materials (No in S166), the distribution planning department 180 performs processing of entrusting the work of detouring the vehicle to the inventory center during the normal distribution of other materials from the material factory to the production base to the transportation company that performs the distribution (step S168). On the other hand, in the case where it is determined that the delay caused by the detour affects the production of products using other materials (Yes in S166), the distribution planning department 180 plans to distribute other materials by a vehicle other than the vehicle that makes the detour. That is, the distribution planning department 180 plans to load the required amount of other materials onto the following vehicle: in the normal distribution plan of other materials as a scheduled operation shift, a vehicle of a shift other than the vehicle that makes the detour (for example, the next shift of the vehicle), and a vehicle that arrives at the production base earlier than the vehicle that makes the detour.

[0146] The distribution planning department 180 calculates the amount of other materials to be loaded onto the vehicle of other shifts (step S170). Specifically, the distribution planning department 180 calculates the amount of other materials that become insufficient before the vehicle that makes the detour arrives at the production base as the amount of other materials to be loaded onto the vehicle of other shifts. More specifically, the distribution planning department 180 can calculate the amount of other materials to be loaded onto the vehicle of other shifts by calculating ("delay time" - "remaining amount of other materials at the production base" × "cycle time of each other material") / "cycle time of each other material".

[0147] Then, the distribution planning department 180 performs the same processing as in S168 for entrusting the work of detouring the vehicle of the normal distribution plan to the inventory center and the work of distributing the amount of other materials calculated in S170 by other shifts to the transportation company that performs the distribution (step S172). Thereby, the influence of the detour of the vehicle for distributing other materials on the production of products using other materials can be suppressed.

[0148] Next, the case where the determination in the processing of S160 is No will be described. In the case where it is determined that the normal distribution plan of distributing other materials from the material factory to the production base cannot be interrupted (No in S160), the distribution planning department 180 plans a detour of the return shift in the normal distribution plan of distributing other materials from the material factory to the inventory center to the production base (step S180). That is, the distribution planning department 180 plans to interrupt the normal distribution plan of distributing other materials from the material factory to the inventory center. In addition, the normal distribution plan may be a scheduled operation shift. In addition, the normal distribution plan corresponds to Figure 1 the logistics of other materials shown by the dotted arrow from the material factory 52 to the inventory center 56 in

[0149] Figure 17This is a diagram for explaining the interruption of the normal delivery plan for delivering other materials from a materials factory to an inventory center that stores insufficient materials. In Figure 17 Material factory 52 is a factory that produces other materials 32b. In addition, inventory center 56 is an inventory center that stores other materials 32b and insufficient materials 32a. In addition, production base 54 is a factory that uses insufficient materials 32a, etc. In this case, the so-called interruption means that after delivering other materials 32b from material factory 52 to inventory center 56 during the regular shift, before the vehicle returns to material factory 52, the vehicle loaded with insufficient materials 32a is diverted to production base 54 midway. That is, as shown by arrow C, after the vehicle delivers other materials 32b from material factory 52 to inventory center 56, as shown by arrow D, the vehicle loaded with insufficient materials 32a at production base 54 is diverted to inventory center 56 midway.

[0150] The delivery planning department 180 determines whether it is possible to deliver the insufficient materials using the vehicles in one shift (step S182). Specifically, the delivery planning department 180 determines whether the available capacity of the vehicle that has delivered other materials to the inventory center is greater than or equal to the occupancy of the insufficient materials. In addition, the calculation methods for the available capacity and occupancy can be substantially the same as those in the process of S160. When the available capacity of the vehicle that has delivered other materials to the inventory center is greater than or equal to the occupancy of the insufficient materials, the delivery planning department 180 determines that it is possible to deliver the insufficient materials using the vehicles in one shift. On the other hand, when the available capacity of the vehicle that has delivered other materials to the inventory center is not greater than or equal to the occupancy of the insufficient materials, the delivery planning department 180 determines that it is not possible to deliver the insufficient materials using the vehicles in one shift.

[0151] When it is determined that the available capacity of the vehicle that has delivered other materials to the inventory center is not greater than or equal to the occupancy of the insufficient materials and it is not possible to deliver the insufficient materials using the vehicles in one shift (No in S182), the delivery planning department 180 determines to perform subsequent processing for multiple return trips (such as the trips after the regular shift) (step S184). On the other hand, when it is determined that the available capacity of the vehicle that has delivered other materials to the inventory center is greater than or equal to the occupancy of the insufficient materials and it is possible to deliver the insufficient materials using the vehicles in one shift (Yes in S182), the delivery planning department 180 performs subsequent processing for one shift.

[0152] The distribution planning department 180 calculates the delay time caused by the detour (step S186). Specifically, the distribution planning department 180 calculates the delay time by subtracting the "normal return time from the inventory center back to the material factory" from the "time required to return from the inventory center via the production base to the material factory". In addition, regarding the calculation method of the "time required to return from the inventory center via the production base to the material factory", the time required to load the insufficient materials at the inventory center can be calculated based on the quantity of the insufficient materials, etc. In addition, the time from the inventory center to the production base can use the time calculated during the determination process of the inventory center by the inventory center determination unit 170. The time from the production base to the material factory can be calculated by calculating the shortest path from the production base to the material factory.

[0153] The distribution planning department 180 determines whether the delay caused by the detour affects the sales stores that supply other materials (step S188). Specifically, the distribution planning department 180 determines that the delay caused by the detour affects the sales stores when the return trip to the material factory due to the return shift is delayed due to the detour, and thus the inventory level of other materials in the inventory center may become zero. In other words, during the period when the return trip to the material factory due to the return shift is delayed due to the detour, if the sales stores that receive the supply of other materials from the inventory center have a demand for other materials, and thus the inventory level of other materials in the inventory center may become zero, the distribution planning department 180 determines that the delay caused by the detour affects the sales stores.

[0154] Here, the distribution planning department 180 can use the demand forecast of other materials to calculate when and by how much the inventory level of other materials in the inventory center decreases. The demand forecast can be calculated by a person based on rules of thumb, etc., or by a computer through machine learning, etc. The demand forecast means that for a certain material, there is such a quantity of demand at this timing. For example, if it is a material whose demand tends to increase according to the season (such as studless snow tires or electrical components, etc.), it is predicted that the demand will increase from just before entering that season.

[0155] Then, the distribution planning department 180 determines whether the inventory level of other materials in the inventory center is equal to or more than the decrease amount of the inventory corresponding to the predicted demand for other materials during the period of the delay time. If it is determined that the inventory level is equal to or more than the decrease amount, the distribution planning department 180 determines that the delay caused by the detour does not affect the sales stores. On the other hand, if it is determined that the inventory level is not equal to or more than the decrease amount, the distribution planning department 180 determines that the delay caused by the detour affects the sales stores.

[0156] When it is determined that the delay caused by the detour does not affect the sales stores that do not provide other materials (No in S188), the Distribution Planning Department 180 commissions the transportation company that conducts the distribution to divert the return trip of the normal shift for distributing other materials from the material factory to the inventory center to the production site (step S190). On the other hand, when it is determined that the delay caused by the detour affects the sales stores that provide other materials (Yes in S188), the Distribution Planning Department 180 plans to distribute other materials using vehicles other than the vehicles that make the detour. That is, the Distribution Planning Department 180 plans to load the required amount of other materials onto the following vehicles: vehicles of shifts other than the vehicle that makes the detour (for example, the next shift of the vehicle) in the normal distribution plan of other materials as a regular operation shift, and vehicles that depart from the material factory to the inventory center before the vehicle that makes the detour returns to the material factory.

[0157] Therefore, the Distribution Planning Department 180 performs the same processing as in S190, which is to commission the transportation company to divert the return trip of the normal distribution plan to the production site and to increase and distribute other materials to the inventory center according to the predicted demand in other shifts (step S194). Thereby, the impact on the sales stores that provide other materials caused by the detour of the vehicles for distributing other materials can be suppressed.

[0158] As described above, the material supply system 1 according to Embodiment 1 is configured to perform a distribution plan for supplying shortage materials from the inventory center determined to supply shortage materials to each of the plurality of production sites. Thereby, the shortage materials can be appropriately distributed from the inventory center to the production sites.

[0159] In addition, the material supply system 1 according to Embodiment 1 is configured to interrupt the distribution plan related to the distribution of other materials different from the shortage materials and perform the distribution plan for the shortage materials. Thereby, since there is no need to prepare vehicles solely for distributing shortage materials, the distribution plan can be efficiently performed.

[0160] In addition, the material supply system 1 according to Embodiment 1 is configured to divert the vehicles that distribute other materials from the material factory to the production site in the distribution plan for distributing other materials from the material factory that produces other materials to the production site to the inventory center, and perform the distribution plan for the shortage materials. Thereby, the shortage materials can be distributed using the existing distribution plan that is already distributing from the material factory to the production site. Therefore, the shortage materials can be efficiently distributed.

[0161] In addition, the material supply system 1 according to Embodiment 1 is configured such that, in the distribution plan for distributing other materials from a material factory that produces other materials to an inventory center, the return trip of the vehicle that has completed distributing other materials to the inventory center detours to the production site to perform the distribution plan for the shortage materials. Thus, it is possible to use the existing distribution plan for distributing from the material factory to the inventory center to distribute the shortage materials. Therefore, it is possible to efficiently distribute the shortage materials.

[0162] (Modification example)

[0163] In addition, the present invention is not limited to the above-described embodiments, and can be appropriately modified without departing from the gist. For example, the order of the steps in the above flowcharts can be appropriately changed. In addition, one or more of the steps in the flowcharts can be omitted. For example, in Figure 14 the flowchart shown, the processes of S152 to S156 can also be omitted.

[0164] In addition, in Figure 12 the flowchart, the information acquisition unit 140 acquires the shortage material information in the process of S106, before the processes after S108, but is not limited to such a configuration. The information acquisition unit 140 can also appropriately acquire the information required in the above processes from the information storage unit 100 at the timing of performing each process (step) after S108.

[0165] In addition, in Figure 14 and Figure 15 the flowchart, in the case where the distribution plan for distributing other materials from the material factory to the production site cannot be interrupted, the distribution plan unit 180 plans to interrupt the distribution plan for distributing other materials from the material factory to the inventory center. However, it is not limited to such a configuration. It is also possible to plan to interrupt the distribution plan for distributing other materials from the material factory to the inventory center regardless of whether the distribution plan for distributing other materials from the material factory to the production site can be interrupted.

[0166] In addition, in the above example, the program can be stored using various types of non-transitory computer readable media and provided to a computer. Non-transitory computer readable media include various types of tangible storage media. Examples of non-transitory computer readable media include magnetic recording media (e.g., floppy disks, magnetic tapes, hard disk drives), magneto-optical recording media (e.g., magneto-optical disks), CD-ROMs, CD-Rs, CD-R / Ws, semiconductor memories (e.g., mask ROMs, PROMs (programmable ROMs), EPROMs (erasable PROMs), flash ROMs, RAMs). Additionally, the program can also be provided to a computer by various types of transitory computer readable media. Examples of transitory computer readable media include electrical signals, optical signals, and electromagnetic waves. Transitory computer readable media can provide the program to a computer via wired communication paths such as wires and optical fibers or via wireless communication paths.

Claims

1. A material supply system, comprising: A shortage amount calculation unit that, when the supply of a material used at multiple production sites stops, calculates the shortage amount of the shortage material for each of the multiple production sites by using usage information related to the use of the shortage material, the production plan of products using the shortage material at each of the multiple production sites, and the remaining amount information indicating the remaining amount of the shortage material at each of the multiple production sites; and An inventory center determination unit that determines the inventory center that supplies the shortage material to each of the multiple production sites in the shortest way by using inventory information related to the shortage material in each of the multiple inventory centers storing the shortage material, information on the time required for movement, i.e., movement information, for obtaining the movement between each of the multiple production sites and each of the multiple inventory centers, and the shortage amount, The material supply system further has a distribution planning unit that makes a distribution plan for supplying the shortage material from the determined inventory center to each of the multiple production sites, The distribution planning unit interrupts the distribution plan related to other materials different from the shortage material to make the distribution plan for the shortage material, The distribution planning unit calculates the delay time caused by diverting the return trip of the vehicle that has delivered the other material to the inventory center in the distribution plan for delivering the other material from the material factory producing the other material to the inventory center to a production site, and determines whether the delay caused by the diversion affects the stores supplying the other material, When it is determined that the delay caused by the diversion does not affect the stores supplying the other material, the distribution planning unit diverts the return trip of the vehicle that has delivered the other material to the inventory center in the distribution plan for delivering the other material from the material factory producing the other material to the inventory center to a production site to make the distribution plan for the shortage material.

2. The material supply system according to claim 1, wherein The shortage amount calculation unit calculates the shortage amount, i.e., the amount by which the shortage material is insufficient at each of the multiple production sites within a specified period.

3. The material supply system according to claim 1 or 2, wherein The inventory center is a logistics warehouse that supplies materials to the market.

4. A material supply method, comprising: When the supply of a material used at multiple production sites stops, calculating the shortage amount of the shortage material for each of the multiple production sites by using usage information related to the use of the shortage material, the production plan of products using the shortage material at each of the multiple production sites, and the remaining amount information indicating the remaining amount of the shortage material at each of the multiple production sites; and Using the inventory information related to the shortage materials in each of the multiple inventory centers for storing and managing the shortage materials, the movement information which is the information on the time required for movement between each of the multiple production sites and each of the multiple inventory centers, and the shortage quantity, determine the inventory center that supplies the shortage materials to each of the multiple production sites in the shortest way. Make a distribution plan for supplying the shortage materials from the determined inventory center to each of the multiple production sites. Interrupt the distribution plan related to the distribution of other materials different from the shortage materials to carry out the distribution plan for the shortage materials. Calculate the delay time caused by diverting the return trips of the vehicles that have completed delivering the other materials to the inventory center in the distribution plan for delivering the other materials from the material factory producing the other materials to the inventory center to the production sites, and determine whether the delay caused by the diversion affects the stores providing the other materials. In the case where it is determined that the delay caused by the diversion does not affect the stores providing the other materials, divert the return trips of the vehicles that have completed delivering the other materials to the inventory center in the distribution plan for delivering the other materials from the material factory producing the other materials to the inventory center to the production sites to carry out the distribution plan for the shortage materials.

Images