Production planning system

Abstract

To provide a production planning system capable of improving the production efficiency across an entire supply chain.SOLUTION: A production planning system includes a first input part, a first optimization part, an overall plan creation part, a second input part, and a second optimization part. The production planning system calculates a first objective variable while satisfying a first constraint condition from first explanatory variable data, creates overall production plan data containing a production termination time of each product to be produced at each production base using the first objective variable, inputs second explanatory variable data containing a change time of formulation between products and a production termination time of each product when producing the products in accordance with the overall production plan data, and calculates a second objective variable by solving an optimization problem in which an objective function minimizes the largest difference out of differences between the production termination time in the overall production plan data, and the production termination time when producing in accordance with the overall production plan data.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a production planning system that creates a production plan when a product is produced at a production base. [Background technology]

[0002] In recent years, due to the diversification of products demanded by customers, it is rare for a single product to be produced from materials to the finished product at a single production base.In addition, there are cases where a single production base switches between producing multiple products, and it is becoming rare for a single product to be produced and shipped to a customer at just one production base. As an example of the process from producing a product from materials to delivering it to a customer, parts used in the production of the product are produced at the production bases of multiple suppliers, etc., and the produced parts are supplied to the production bases of manufacturers, etc., who then use the parts to produce the product (for example, Patent Document 1). The products produced by the manufacturers, etc. are then transported to a shipping base, and shipped from the shipping base to the customer, whereupon the products reach the customer. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-073329 Summary of the Invention [Problem to be solved by the invention]

[0004] In relationships between suppliers and manufacturers, the parts production bases and the product production bases are often located in different regions, and even within a single manufacturer, there are cases where separate production bases are established in multiple regions. In these cases, in addition to production costs, transportation costs between production bases and storage costs at each production base are incurred. Therefore, transportation costs and storage costs must be taken into consideration when managing product costs.

[0005] Therefore, there has been a demand for a production plan that can further improve profits throughout the supply chain by suppressing inventory generation at production bases and shortening inventory storage periods, thereby reducing storage operations and lowering storage costs. There has also been a demand for a highly appropriate production plan that can suppress problems caused by production delays at production bases. When formulating such a production plan, there has been a desire to create a highly accurate production plan in a short amount of time and with as little human intervention as possible.

[0006] Therefore, an object of the present invention is to provide a production planning system that can improve production efficiency throughout the entire supply chain. [Means for solving the problem]

[0007] One aspect of the present invention for solving the above-mentioned problems is a production planning system for producing a plurality of types of products through the production of products at a plurality of production bases, and shipping the products from a shipping base directly from the production bases or via a relay base, the system comprising: a first input unit for inputting first explanatory variable data including the type, number, and timing of products required to be produced; a first optimization unit for calculating a first objective variable including the production volume of the products at each production base from the first explanatory variable data inputted to the first input unit by solving an optimization problem having an objective function of minimizing costs while satisfying a first constraint; and an overall plan creation unit for creating overall production plan data including the production completion time of each product produced at each production base using the first objective variable calculated by the first optimization unit. a second input unit that inputs second explanatory variable data including a time period for changing recipes between products and a production end time of each product when each product is produced at a single production base in accordance with the overall production plan data; and a second optimization unit that calculates, from the second explanatory variable data input to the second input unit, a second objective variable including a production sequence and a production start time of each product at the single production base by solving an optimization problem whose objective function is to minimize, while satisfying a second constraint condition, the largest difference between the production end time of a product at the single production base in the overall production plan data and the production end time of each product when produced at the single production base in accordance with the overall production plan data.

[0008] According to this aspect, the storage period of inventory at production bases is short, and highly accurate production plans can be made that can prevent problems caused by production delays at production bases, thereby improving production efficiency throughout the supply chain.

[0009] In a preferred aspect, the second optimization unit is capable of calculating each second objective variable at each production base by solving an optimization problem from each second explanatory variable data, and includes an individual plan creation unit that uses each second objective variable calculated by the second optimization unit to create individual production plan data including a production sequence and a production start time of the products at each production base.

[0010] This aspect can further improve production efficiency throughout the supply chain. In addition, by creating overall production plan data and individual production plan data, it is possible to reduce the amount of calculation required to create overall production plan data, thereby shortening the time required to create a production plan.

[0011] In a preferred aspect, the first input unit is capable of inputting, as the first explanatory variable data, the difference between the production end time of each product at each production base in the overall production plan data and the production end time of each product when produced at each production base in accordance with the overall production plan data, and when each difference is input to the first input unit, the first optimization unit solves an optimization problem taking each difference into account to re-calculate the first objective variable, and the overall plan creation unit updates the overall production plan data using the first objective variable re-calculated by the first optimization unit.

[0012] According to this aspect, it is possible to create overall production plan data that takes into account the actual production situation, and the accuracy of the overall production plan data can be further improved.

[0013] In a preferred aspect, the overall production plan data is a production plan for a first period, in which the first period is divided into a plurality of second periods and a production volume at each production base is planned for each of the plurality of second periods, and when a third period that is shorter than the first period and shorter than the shortest of the second periods has passed, the difference is calculated and input to the first input unit as the first explanatory variable data.

[0014] According to this aspect, the overall production plan data is updated to reflect the actual production situation before the first period has elapsed, making it possible to carry out production according to a production plan based on the updated overall production plan data, thereby further improving production efficiency throughout the supply chain.

[0015] In a preferred aspect, the costs include at least one of the following costs (1) to (7): (1) Production costs at each production site (2) Costs of changing product recipes at each production site (3) Inventory storage costs for materials and products at each production site (4) Transportation costs between production sites (5) Transportation costs from the most downstream production base to the relay base and / or shipping base (6) Penalty costs due to production delays (7) Cost of external purchase of raw materials and / or ingredients

[0016] This aspect makes it possible to create overall production plan data that takes into account production costs at each production base, formulation change costs, inventory storage costs, transportation costs, penalty costs due to production delays, etc. This makes it possible to create production plans that can reduce the total cost up to shipment compared to conventional methods.

[0017] In a preferred aspect, the first constraint condition includes at least one of the following (10) to (17). (10) Batch-by-batch production costs at each production site (11) Batch production time at each production site (12) Batch production volume at each production site (13) Safety stock at each production site (14) Upper and / or lower limits on production volume per cycle at each production site (15) Upper and / or lower limits on production volume at each production site within a given period (16) Upper and / or lower limits on production time at each production site within a given period (17) The upper limit of inventory at the relay point and / or shipping point

[0018] According to this aspect, it is possible to create a more accurate production plan according to the actual production capacity and inventory storage capacity.

[0019] In a preferred aspect, the plurality of types of products includes a foam-molded product, and the second constraint condition includes at least one of the following (20) to (27). (20) Production sequence among specific products (21) Production interval between products (22) Product curing and filling times (23) Upper limit of simultaneous foaming series (24) Upper limit of simultaneous filling series (25) Upper limit of same-color filling series (26) The period from the production of the product to the shipment of the product from the shipping base. (27) Limit on the number of recipe changes between products

[0020] According to this aspect, when producing a plurality of types of products including foam molded products, it is possible to create a more accurate production plan according to the actual production capacity.

[0021] In the above-mentioned preferred aspect, it is more preferable that the cost includes a cost value according to the following (28) and a cost value according to the following (29), the first explanatory variable data includes the following (30) to (41), and the calculation of the second objective variable solves an optimization problem having an objective function of minimizing the following (42), the second explanatory variable data includes the following (43), the second objective variable includes the following (30) to (33), (36) to (39), and (40), and (30) to (33), (36) to (39), and (40) in the second objective variable are fed back to (30) to (33), (36) to (39), and (40) in the first explanatory variable data. (28) Prescription change reduction costs (29) Similarity with past overall production plan data (30) Preparation costs for each product type at each production site and / or each manufacturing line (31) Preparation time for each product type at each production site and / or each production line (32) Recipe change costs for each production site and / or each production line (33) Recipe change time for each product type at each production site and / or each production line (34) Costs of reducing prescription changes by priority product type for each production site and / or each manufacturing line (35) Time required to reduce prescription changes by priority product type for each production site and / or each manufacturing line (36) Preparation costs for each production facility and / or each production line by product type and period (37) Preparation time for each production facility and / or each production line by product type and period (38) Recipe change costs by product type and period for each production site and / or each manufacturing line (39) Recipe change time by product type and period for each production site and / or each production line (40) The degree of similarity with the combination of product varieties that have been produced simultaneously by period at each production base and / or each production line, and the degree of recommendation for simultaneous production (41) Production volume by product type and period based on past overall production plan data, and the number of overall production plan data to be acquired (42) Similarity with past individual production plan data (43) The production volume by product type and time based on past individual production plan data, and the number of individual production plan data to be acquired

[0022] According to this aspect, it is possible to create more accurate overall production plan data and individual production plan data based on actual production results.

[0023] The above aspects may be made dependent on each other, or some of the configurations may be quoted or substituted for each other, as long as they are included in the technical scope of the present invention. [Effects of the Invention]

[0024] The present invention can provide a production planning system that can improve production efficiency throughout the entire supply chain. [Brief explanation of the drawings]

[0025] [Figure 1] 1 is a configuration diagram of a production planning system according to an embodiment of the present invention. [Figure 2] FIG. 2 is an explanatory diagram schematically showing a flow from production of a product to transportation to a consumer in the production planning system of FIG. 1. [Figure 3] (a) is a block diagram showing the first production base in Figure 1, (b) is a block diagram showing the second production base in Figure 1, (c) is a block diagram showing the third production base in Figure 1, and (d) is a block diagram showing the fourth production base in Figure 1. [Figure 4] 2A is a block diagram showing the relay point in FIG. 1, and FIG. 2B is a block diagram showing the shipping point in FIG. [Figure 5] FIG. 2 is a block diagram illustrating the management computer of FIG. 1. [Figure 6] 2 is a diagram showing an example of overall production plan data created by the production planning system of FIG. 1. FIG. [Figure 7] 2 is a diagram showing an example of individual production plan data created by the production planning system of FIG. 1. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0026] Hereinafter, embodiments of the present invention will be described in detail.

[0027] The production planning system 1 of this embodiment produces a product 100 in response to a production request from a consumer, and ships the product 100 to the consumer. Specifically, as shown in Fig. 1, the production planning system 1 includes one or more first production bases 10, one or more second production bases 11, one or more third production bases 12, one or more fourth production bases 13, a relay base 14, and a shipping base 15. The production planning system 1 also includes a management computer 16. Then, production, transportation, and shipping can be carried out at each base according to production plan data (described in detail below) created by the management computer 16.

[0028] 2, the production planning system 1 can produce the product 100 by carrying out intermediate production and processing for producing the final product 100 at a first production base 10, a second production base 11, and a third production base 12, and then carrying out final production and processing at a fourth production base 13. The production planning system 1 can then ship the product 100 from a shipping base 15 directly from the fourth production base 13 or via a relay base 14. In addition, the production planning system 1 of this embodiment can perform intermediate production and processing of the product 100 at the first production base 10 and the second production base 11, and produce the product 100 at the fourth production base 13.

[0029] That is, the production planning system 1 can produce the product 100 by carrying out intermediate production and processing at one or more production bases selected from the first production base 10 to the fourth production base 13, and carrying out final production and processing at another production base. Furthermore, although detailed illustration is omitted, the production planning system 1 can ship products produced at each of the first production base 10, second production base 11, and third production base 12 from a shipping base 15 directly from each base or via a relay base 14. In the following explanation, an example will be given in which intermediate production and processing are carried out at the first production base 10, the second production base 11, and the third production base 12, and final production and processing is carried out at the fourth production base 13.

[0030] (First production base 10) 2, the first production base 10 is a base that produces a first intermediate product 101 as a product, which is a material (first material) for intermediate products (second intermediate products 102a, 102b) produced at the second production base 11. As shown in FIG. 3, the first production base 10 includes one or more first production devices 20 and a first management warehouse 21. The first production device 20 is capable of producing one or more types of materials (first intermediate products 101) from one or more types of raw materials in accordance with production plan data (described in detail later). More specifically, the first production base 10 of this embodiment has one or more production lines (first production lines) configured to include one or more first production devices 20. The first management warehouse 21 is a warehouse that stores various types of first intermediate products 101 produced by the first production equipment 20 and various types of raw materials used in the first production equipment 20. The plurality of first production bases 10 may each produce the same type of material (first intermediate products 101), or may each produce different types of materials (first intermediate products 101).

[0031] (Second production base 11) As shown in Figure 2, the second production site 11 is a site to which one or more types of materials (first intermediate product 101) are supplied from one or more first production sites 10. The second production site 11 is also a site that produces, as a product, an intermediate product (second intermediate product 102a) that will be the material (second material) of a third intermediate product 103 produced at the third production site 12. The second production site 11 is also a site that produces, as a product, an intermediate product (second intermediate product 102b) that will be the material (third material) of a product 100 produced at the fourth production site 13. As shown in FIG. 3, the second production base 11 includes one or more second production devices 24 and a second management warehouse 25. The second production device 24 is a device that produces one or more types of intermediate products (second intermediate products 102a) that will be used as materials for the third intermediate product 103 described above, and one or more types of intermediate products (second intermediate products 102b) that will be used as materials for the product 100 described above. The second production device 24 is capable of producing multiple types of intermediate products (second intermediate products 102a, second intermediate products 102b) from materials including one or multiple types of materials (first intermediate products 101) produced at the first production base 10 in accordance with production plan data (described in detail below). More specifically, the second production base 11 of this embodiment has one or more production lines (second production lines) configured to include one or more second production devices 24. The second management warehouse 25 is a warehouse that stores various types of intermediate products (second intermediate products 102a, second intermediate products 102b) produced by the second production equipment 24 and various types of materials (first intermediate products 101) used by the second production equipment 24 as inventory. The plurality of second production bases 11 may each produce the same type of material (intermediate product), or may produce different types of material.

[0032] (Third production base 12) 2, the third production site 12 is a site to which one or more types of materials (second intermediate products 102a) are supplied from one or more second production sites 11. The third production site 12 is also a site that produces intermediate products (third intermediate products 103) as products that will be used as materials (fourth materials) for the products 100 produced at the fourth production site 13. As shown in FIG. 3, the third production base 12 includes one or more third production devices 28 and a third management warehouse 29. The third production device 28 is a device that produces one or more types of intermediate products (third intermediate products 103) that will be used as materials for the products 100 produced at the fourth production base 13. The third production device 28 is capable of producing one or more types of intermediate products (third intermediate products 103) from materials including one or more types of materials (second intermediate products 102a) produced at the second production base 11 in accordance with production plan data (described in detail below). More specifically, the third production base 12 of this embodiment has one or more production lines (third production lines) configured to include one or more third production devices . The third management warehouse 29 is a warehouse that stores various types of intermediate products (third intermediate products 103) produced by the third production equipment 28 and various types of materials (second intermediate products 102a) used by the third production equipment 28 as inventory. The plurality of third production bases 12 may produce the same type of material (third intermediate product 103) or different types of materials.

[0033] (4th production base 13) The fourth production base 13 is a base that receives one or more types of intermediate products (second intermediate products 102b, third intermediate products 103) from one or more second production bases 11 and / or one or more third production bases 12, and produces the product 100 as a finished product. In other words, the fourth production base 13 functions as a product production base. As shown in FIG. 3, the fourth production base 13 includes one or more fourth production devices 32 and a fourth management warehouse 33. The fourth production device 32 is a device that produces the product 100, and specifically, is a processing device that processes intermediate products (second intermediate product 102b, third intermediate product 103). More specifically, the fourth production base 13 of this embodiment has one or more production lines (fourth production lines) configured to include one or more fourth production devices 32. The fourth production device 32 is capable of producing multiple types of products 100 from materials including one or multiple types of intermediate products produced at the second production site 11 and / or one or multiple types of intermediate products produced at the third production site 12 in accordance with production plan data (described in detail below). The fourth management warehouse 33 is a warehouse that stores, as inventory, each type of product 100 produced by the fourth production equipment 32 and each type of material (second intermediate product 102a, third intermediate product 103) used by the fourth production equipment 32. The plurality of fourth production bases 13 may each produce the same type of product 100, or may produce different types of products 100.

[0034] The production planning system 1 of this embodiment includes a foam molded product as one type of product. When producing foam-molded products, the first production site 10 functions as a production site that produces pellets (mini-pellets) as first intermediate products 101 from raw materials. The second production site 11 functions as a production site that produces intermediate products by performing one-stage foaming (pre-foaming) on ​​the material. The third production site 12 functions as a production site that produces intermediate products by performing two-stage foaming (the second time when pre-foaming is used to make multi-stage foaming) on ​​the material. The fourth production site 13 is a production site that performs foam molding, that is, a production site that functions as a so-called molder.

[0035] (Relay point 14) The relay base 14 is a base that serves as a relay point for the transportation of one or more types of products 100, mainly from one or more fourth production bases 13, and when the produced products 100 are shipped from the fourth production bases 13 to the shipping base 15. The relay station 14 includes a relay management warehouse 36 as shown in FIG. The relay management warehouse 36 is a warehouse that temporarily stores the products 100 transported from the fourth production base 13 and the like.

[0036] (Shipping base 15) The shipping base 15 is a base where one or more types of products 100 are transported from one or more fourth production bases 13 or one or more relay bases 14, and where the products 100 produced at the fourth production bases 13 are shipped to consumers. As shown in FIG. 4, the shipping base 15 includes a shipping management warehouse 39. The shipping management warehouse 39 is a warehouse that stores the products 100 transported from the fourth production base 13 directly or via the relay base 14 as inventory.

[0037] In addition, the first production base 10 to the fourth production base 13, the relay base 14, and the shipping base 15 each have terminals (first terminal to sixth terminal) not shown, and are connected to the management computer 16 via a network in a state where signals (information) can be sent and received. Each terminal is a computer with a hardware configuration that includes a central processing unit consisting of a control device that controls each device and an arithmetic unit that performs calculations on data, a memory device that stores data, an input device that inputs data from the outside, and an output device that outputs data to the outside. In addition, one or more of the terminals at each base may also function as the management computer 16.

[0038] (Administrative Computer 16) The management computer 16 is a computer having a hardware configuration including a central processing unit consisting of a control device that controls each device and an arithmetic unit that performs calculations on data, a memory device that stores data, an input device that inputs data from the outside, and an output device that outputs data to the outside.

[0039] As shown in FIG. 5, the management computer 16 includes a first input unit 45, a first optimization unit 46, an overall plan creation unit 47, a second input unit 48, a second optimization unit 49, an individual plan creation unit 50, an output unit 51, and a data storage unit 52.

[0040] The first input section 45 is a section for inputting first explanatory variable data. The first input unit 45 is capable of inputting the input first explanatory variable data to the first optimization unit 46 . The first input unit 45 may acquire part of the first explanatory variable data from the data accumulation unit 52 and input it to the first optimization unit .

[0041] The first optimization unit 46 is a part that calculates objective variables from the first explanatory variable data input to the first input unit 45 by solving an optimization problem whose objective function is to minimize (make most advantageous) costs including one or more of the costs (a-1) to (a-6) below while satisfying the first constraint condition, and creates first objective variable data. The optimization problem solved by the first optimization unit 46 of this embodiment has an objective function of minimizing the total cost consisting of the following costs (a-1) to (a-6). (a-1) Production costs of products at each production site (a-2) Cost of changing product recipes at each production site (a-3) Inventory storage costs for materials and products at each production site (a-4) Transportation costs between production bases (a-5) Transportation costs from the most downstream production base to the relay base 14 and / or shipping base 15 (a-6) Penalty costs due to production delays

[0042] That is, the first optimization unit 46 calculates the objective variables by solving an optimization problem whose objective function is to minimize the production costs of the products (first intermediate product 101 to third intermediate product 103, product 100) using each production device (first production device 20 to fourth production device 32) at each production base (first production base 10 to fourth production base 13), the cost of changing the recipe of each production device, the inventory storage costs at each management warehouse (first management warehouse 21 to fourth management warehouse 33, relay management warehouse 36, shipping management warehouse 39), the transportation costs between each production base, the transportation costs from the most downstream production base to the relay base 14 and / or shipping base 15, and the penalty costs when the shipping delivery date of the product is delayed or the operating time of each production device is exceeded, and creates first objective variable data.

[0043] "Production costs" include preparation costs incurred during the preparation stage of production, such as costs incurred when setting up a new line or ordering new base materials or parts (such as molds). Furthermore, the "production cost" may be the production cost for a predetermined period (for example, one year, which is the first period described below). In this case, the "production cost" may be at least one of the production costs that may occur in all of the predetermined period divided into multiple periods (production cost common to all periods) and the production costs that may occur in each individual period (production cost by period). In other words, when creating the first objective variable data described above, the objective variable may be calculated by solving an optimization problem whose objective function is to minimize at least one of the production cost common to the entire period and the production cost by period, and the costs (a-2) to (a-6). Furthermore, the "production cost" may be the production cost for each type (variety) of product, or products may be grouped in advance into groups of similar types and the production cost for each group may be calculated. In more detail, when products are grouped, a pre-set production cost is incurred, for example, a cost X for a product belonging to group A, a cost Y for a product belonging to group B, etc. By grouping in this way, the production planning system 1 of this embodiment can reduce the amount of calculation. Note that the "production cost" is not limited to the actual value of the production cost, but may also be a set value corresponding to the production cost. This also applies to the other items below. "Recipe change costs" are costs incurred by changing recipes, such as switching the type (variety) of product, changing the ratio of raw materials (ingredients), or changing the number of processes. Furthermore, the "prescription change cost" may be the prescription change cost for a predetermined period (for example, a one-year first period described below). In this case, the "prescription change cost" may be at least one of the prescription change costs that may occur in all of the predetermined period divided into multiple periods (prescription change cost common to the entire period) and the prescription change costs that may occur in each individual period (prescription change cost for each period). In other words, when creating the first objective variable data described above, the objective variable may be calculated by solving an optimization problem whose objective function is to minimize at least one of the prescription change cost common to the entire period and the prescription change cost for each period, and the costs of (a-1) and (a-3) to (a-6). Furthermore, "recipe change costs" are not incurred when the same product is produced at the same location across two separate periods. For example, if production continues until the end of the previous day on the same production line at the same production base, and then begins again at the start of the next day, "recipe change costs" are not incurred. The "cost incurred by switching the type of product" mentioned above may be the cost incurred by grouping products of similar types in advance and switching from a product belonging to one group to a product belonging to another group. In more detail, when products are grouped, a preset switching cost is incurred, such as cost X when switching from a product belonging to group A to a product belonging to group B, and cost Y when switching from a product belonging to group B to a product belonging to group C. "Inventory storage costs" include the ongoing storage costs of each management warehouse and the costs of entering and leaving the warehouse. "Continuous storage costs" are costs incurred when storing products, etc. for a certain period of time, and are costs that are incurred continuously depending on the number of days of storage. "Inbound and outbound costs" are costs incurred when products are received into or shipped out of a management warehouse, and are costs incurred per inbound and per shipment.

[0044] In addition to (a-1) to (a-6) above, or instead of one or more of (a-1) to (a-6) above, one or more of the costs listed below in (a-7) to (a-12) may be added to the total cost. (a-7) Transportation costs from each management warehouse to the consumer (a-8) Penalty costs when orders are delinquent (a-9) Transportation cost from relay point 14 to shipping point 15 (a-10) External purchase costs of raw materials and / or ingredients (a-11) Prescription change reduction costs (a-12) Similarity with past plans

[0045] (a-11) is a cost value corresponding to the cost reduction when a product type is changed from a predetermined type to another type at each production base and / or each production line. For example, if the cost reduction achieved by changing the recipe from product X to product A at a production line at a predetermined production base is XXXX yen, compared to changing the recipe from product X to product A, the cost reduction is XXXX yen. In this embodiment, (a-11) is a cost value corresponding to such a reduction in cost, and the cost value is a preset value, and the higher the reduction in cost, the lower the value. Furthermore, as described above, (a-11) may be the cost when products are pre-grouped by similar type. In other words, it may be information indicating the cost reduction when a product type belonging to a predetermined product group is changed to a product belonging to another product group. In this case, the cost reduction due to the change is pre-set for each combination of product groups. The "similarity with past plans" in (a-12) refers to the similarity with overall production plan data 60 (described in detail later) created in the past, and the higher the similarity, the lower the preset cost value. Here, the "similarity to the past plan" is evaluated based on the degree of approximation to the past overall production plan data 60 for each preset item. For example, if the same type of product as in the past overall production plan data 60 is produced, 10 points are added to the evaluation score. If a different type of product is produced, a score between 0 and 9 points is added depending on the degree of similarity between the types of products that is preset. Furthermore, even if the same product is produced, if it is produced on the same production line at the same production base, an additional evaluation score is added. In other words, the "similarity with the past plan" is a value determined by the magnitude of the distance between data for each item (the difference between data). In the production planning system 1 of this embodiment, the above items are predetermined based on the type of product to be produced, the production location of the product (production base and production line), the combination of multiple products to be produced within a predetermined period, and the production time of the product. From the above, the production planning system 1 calculates the first objective variable data by adding (a-11) to the total cost so that the first objective variable data is closer to the first objective variable data used when creating the overall production plan data 60 created in the past.

[0046] The optimization method for solving the optimization problem is not particularly limited, but for example, mathematical optimization, metaheuristic optimization, quantum computer, and deep reinforcement learning can be adopted. An example of mathematical optimization is mixed integer programming. Metaheuristic optimization includes, for example, tabu search and genetic algorithms. An example of a quantum computer is Quadratic Unconstrained Binary Optimization (QUBO), which uses a quantum annealing machine. An example of deep reinforcement learning is Deep Q-Network.

[0047] The first explanatory variable data input to the first optimization unit 46 from the first input unit 45 includes one or more of the following (b-1) to (b-27), and in this embodiment includes all of (b-1) to (b-24). (b-1) The amount of raw materials and / or ingredients received (procurement amount) by type, and / or the date of arrival (procurement period) (b-2) External purchase costs of raw materials and / or ingredients (b-3) Purchase quantity per unit of raw materials and / or ingredients (b-4) Demand (sales volume) (b-5) Production costs per batch at each production site and / or each manufacturing line (b-6) Production time per batch at each production site and / or each production line (b-7) Production volume per batch at each production site and / or each manufacturing line (b-8) Production availability and production capacity for each type (product) at each production site and / or each production line (b-9) Maximum operating hours of each production site and / or each production line (b-10) Minimum production volume per continuous production run at each production site and / or each manufacturing line (b-11) Maximum production volume per continuous production run at each production site and / or each manufacturing line (b-12) The amount of intermediate product (upstream product) required for product 100 (final product) (b-13) Preparation costs for each production site and / or each manufacturing line (b-14) Initial inventory at each management warehouse (b-15) Storage fee per unit (b-16) Shipping fee and / or shipping fee per unit (b-17) Safety stock (b-18) Inventory quantity upper limit (b-19) Maximum stock amount (b-20) Transportation costs from each management warehouse to other management warehouses or consumers (b-21) Transportation time from each management warehouse to other management warehouses or consumers (b-22) Penalty costs when orders are delinquent (b-23) Relaxation time for maximum operating hours at each production site and / or each manufacturing line (b-24) Possibility of simultaneous production at each production base and / or each production line (b-25) Possibility of transportation from each management warehouse to other management warehouses or consumers (b-26) Upper and / or lower limits of production volume for each production site and / or each production line within a specified period (b-27) Upper and / or lower limits of production time within a given period at each production site and / or each production line (b-28) Preparation costs for each production site and / or each production line by type (product) (b-29) Preparation time for each production site and / or each production line by type (product) (b-30) Recipe change costs by type (product) of each production site and / or each production line (b-31) Recipe change time by type (product) of each production site and / or each production line (b-32) Cost reduction of prescription changes by priority product type at each production site and / or each manufacturing line (b-33) Time required to reduce prescription changes by priority product type at each production site and / or each manufacturing line (b-34) Preparation costs by type (product) and period for each production site and / or each production line (b-35) Preparation time by type (product) and period for each production site and / or each production line (b-36) Recipe change costs by type (product) and period for each production site and / or each production line (b-37) Recipe change time by type (product) and period for each production site and / or each production line (b-38) Similarity with the combination of varieties (products) that have been produced simultaneously by period at each production base and / or each production line, and the degree of recommendation for simultaneous production (b-39) Production volume by type (product) and period based on past overall production plan data 60, and the number of target overall production plan data 60

[0048] In this embodiment, the above (b-1) is a collection of information related to the arrival of raw materials and / or materials. In detail, (b-1) may be a collection of multiple sets of information in which information indicating (specifying) raw materials or ingredients (in this example, raw materials), information indicating the amount of arrival, and information indicating the arrival date are associated, for example, (Raw material XX, 1 ton, January 23, 2024). In this embodiment, the above (b-2) is a set of information relating to external purchase costs (a set of information in which one or more pieces of information are associated with information indicating external purchase costs). In detail, (b-2) may be a collection of multiple sets of information in which information indicating a production base, information indicating the type (product) of purchased raw materials or ingredients, information indicating the destination, and information indicating external purchase costs are associated, for example, like (first production base 10, product type A, destination XX, 1000 yen). In other words, the above (b-2) may include one or more of the external purchasing costs by production base, by type (product), and by destination. Also, (b-2) may be the external purchasing costs corresponding to two or more elements of by production base, by type (product), and by destination, such as the external purchasing costs by destination for each type at each production base (in this example, it corresponds to three elements: by production base, by type, and by destination). The "per unit" in (b-3) above is a predetermined unit (order unit, transaction unit, etc.) such as one bag unit or one box unit. (b-3) may include one or more of the purchase amount per unit by production base, the purchase amount per unit by type (product), and the purchase amount per unit by destination. Also, similar to the above, (b-3) may be the purchase amount per unit corresponding to two or more elements of the production base, the type (product), and the destination. The above (b-4) may include one or more of the demand amount by type (product), the demand amount by period, and the demand amount by destination, or may be a demand amount corresponding to two or more elements of the demand amount by type (product), the period, and the destination, as in the above. That is, (b-4) may be a collection of information related to the demand amount. In detail, for example, (b-4) may be a collection of multiple sets of information that associate information indicating the demand object, information indicating the demand amount, information indicating the destination, and information indicating dates such as the order date and delivery date, such as (product A, 1 ton, destination XX, February 23, 2024). In this embodiment, (b-4) includes the type, number of products, and timing of production of the product (e.g., product 100) requested by the consumer (and / or other production base). The above (b-5), (b-6), and (b-7) refer to the production cost, production time, and production volume per batch when a predetermined quantity is defined as one batch and a process is performed in batch units to produce a product. While not particularly limited, they may also be the production cost, production time, and production volume per batch when a single production run in a batch plant is controlled to be a discrete value of one batch. Furthermore, "each production line" refers to a production line that belongs to one of the production bases, and includes one or more production devices. In other words, instead of or in addition to "the production cost, production time, and production volume per batch on each production line," they may be "the production cost, production time, and production volume per batch on one or more production devices." Furthermore, the above (b-5), (b-6), and (b-7) may include the production cost, production time, and production volume per batch for each type (product) at each production base and / or each production line. Furthermore, the above (b-5) may be a collection of information relating to the production cost per batch. In detail, for example, the above (b-5) may be a collection of a plurality of sets of information that associate information indicating a production base, information indicating a production line, information indicating the type (product) of raw materials or materials, and information indicating the production cost per batch, such as (first production base 10, production line X1, product type D, 10,000 yen). Similarly, the above (b-6) and (b-7) may be expressed as "a collection of information relating to production time per batch" and "a collection of information relating to production volume per batch", respectively. The above (b-8) is information indicating whether each production base and / or each production line can produce each product by type, and information indicating the production capacity if production is possible. The above (b-8) may be a collection of information related to production capacity. In detail, for example, (b-8) may be a collection of multiple sets of information in which information indicating a production base and / or information indicating a production line is associated with information indicating a product type (product) and information indicating a producible amount, such as (second production base 11, production line Y1, product type B, 25 tons). In this example, it can be seen that the production line Y1 of the second production base 11 is capable of producing 25 tons of product type B. Similarly, (b-9) above may be "the maximum operation time of one or more production devices" instead of or in addition to "the maximum operation time of each production line." Furthermore, (b-9) above may be the maximum operation time (for a predetermined period) for each production base and / or each production line. (b-9) above may be a collection of information related to maximum operation time. Specifically, (b-9) above may be a collection of multiple pieces of information in which information indicating the maximum operation time (maximum operation time per period) is associated with information indicating the production base and / or production line, such as (second production base 11, production line Y1, 400 hours / month). The "per period" may be a period based on length, such as one month or one week, or may be a period from a predetermined start date to an end date, such as March 2023. This also applies when simply referring to "period" in data (information) belonging to other first explanatory variable data. The above (b-10) includes the minimum production volume for each type (product) per continuous production run (one cycle) at each production base and / or each production line. That is, (b-10) is information (data) indicating the minimum amount that must be produced once production begins at a specific production base and / or a specific production line, and more specifically, includes information indicating the minimum amount that must be produced once production of a specific type (product) begins. That is, (b-10) includes the lower limit of the production volume per cycle at each production base. (b-10) may be a collection of information related to the minimum continuous production volume. In detail, for example, (b-10) may be a collection of a plurality of sets of information in which information indicating a production base and / or information indicating a production line is associated with information indicating the type of product (product) and information indicating the minimum production volume per continuous production (in one cycle), such as (second production base 11, production line Y1, type D, 5 batches). (b-11) includes the maximum production volume by type (by product) per continuous production run (one cycle) at each production base and / or each production line. That is, (b-11) is information (data) indicating the maximum amount that can be produced in one production run at a specified production base and / or a specified production line, and more specifically, includes information indicating the maximum amount of a specified type (product) that can be produced in one run. That is, (b-11) includes the upper limit of the production volume per cycle at each production base. Like (b-10), (b-11) may be a collection of information regarding the minimum continuous production volume. (b-12) may be a collection of information related to a bill of materials (BOM). In detail, for example, (b-12) may be a collection of a plurality of sets of information in which information indicating a production base and / or information indicating a production line is associated with information indicating a final product (the type of the final product), information indicating a required intermediate product (the type of the intermediate product), and information indicating a required quantity of the intermediate product, such as (second production base 11, production line Y1, final product XA, intermediate product YA, 1.02). (b-13) may or may not take into account the product recipe (or recipe changes between products). If these are not taken into account, a uniform preparation cost is assumed to be incurred at each production base or each production line. (b-13) may be a collection of information related to the preparation cost. In detail, for example, (b-13) may be a collection of multiple sets of information in which information indicating the production base and / or information indicating the production line is associated with information indicating the preparation cost, such as (second production base 11, production line Y1, 2,000 yen). The preparation cost in (b-13) of this embodiment is a predicted value (theoretical value) set based on simulations and surveys conducted in advance. (b-14) includes the initial inventory amount by type (product) of each management warehouse. The "storage fee per unit" in (b-15) is the fee incurred when storing the object (raw materials, ingredients, products, etc.) in one occupied area unit (one pallet, etc.) for a certain period of time, and includes one or more of the storage fee per unit (by management warehouse) at each management warehouse, the storage fee per unit by type (product), and the storage fee per unit by period. Also, (b-15) may be a storage fee per unit corresponding to two or more elements of the management warehouse, type, and period, as above. The "delivery fee per unit" in (b-16) is the delivery fee (transportation cost) per specified unit quantity, and the "warehouse entry / exit fee per unit" is the warehouse entry / exit fee (warehouse entry / exit cost) per specified unit quantity. The "safety stock" in (b-17) is the minimum amount of inventory to be secured (lower limit inventory amount), and may include one or more of the following: safety stock (by management warehouse) at each management warehouse, safety stock by type (product), and safety stock by period. Also, (b-17) may be safety stock corresponding to two or more elements, by management warehouse and by period, as above. In other words, (b-17) includes safety stock at each production base. (b-18) may include one or more of the upper limit of inventory quantity (upper limit of inventory quantity) at each management warehouse, the upper limit of inventory quantity by type (product), and the upper limit of inventory quantity by period. Also, (b-18) may be the upper limit of inventory quantity corresponding to two or more elements of the upper limit of inventory quantity by management warehouse, the upper limit of inventory quantity by type (product), and the upper limit of inventory quantity by period, as above. In other words, (b-18) includes the upper limit of inventory (inventory quantity) at the relay base 14 and / or the shipping base 15. The "maximum inventory amount" in (b-19) is the maximum inventory amount converted into the occupied area in this embodiment, and may include one or more of the maximum inventory amount by management warehouse and the maximum inventory amount by period, or may be the maximum inventory amount corresponding to two elements. In other words, (b-18) includes the upper limit of the maximum inventory amount converted into the occupied area at the relay base 14 and / or the shipping base 15. (b-20) is the transportation cost from each management warehouse to other management warehouses or consumers (from each base to other bases or consumers), and is the transportation cost by destination (by each warehouse and / or by each customer). (b-21) is the transportation time from each management warehouse to another management warehouse or consumer (from each base to another base or consumer), and is the transportation time by destination (by each warehouse and / or by each customer). (b-22) is a penalty cost in a predetermined unit (one batch unit in this embodiment) when an order is delinquent, and may include one or more of a penalty cost by production base, a penalty cost by type (product), and a penalty cost by destination. As above, (b-22) may also be a penalty cost corresponding to two or more elements of a production base, a type (product), and a destination. In this embodiment, it is a collection of information related to penalty costs. In detail, (b-22) may be a collection of multiple sets of information that associate information indicating a production base, information indicating the type (product) of the delinquent product, and information indicating the destination, for example, (second production base 11, type D, destination A, 20,000 yen). The "relaxation time of maximum operating time" in (b-23) is the difference between the production end time of a product in the overall production plan data 60 (details will be described later) and the production end time of the same product in the individual production plan data 61 (details will be described later) related to the same production plan. Specifically, in previously created production plan data (total production plan data 60, individual production plan data 61), it is the difference between the value (theoretical value) of the production end time of a product in the total production plan data 60 and the value (theoretical value) of the production end time of the same product in the individual production plan data 61 that corresponds to a part of the total production plan data 60 in the same production plan data (details will be described later). Note that if the production end times of multiple products (e.g., product A, product B, product C) can be obtained in both the total production plan data 60 and the individual production plan data 61, the "difference" here refers to the difference for each product, i.e., the difference between the production end time of product A in the total production plan data 60 and the production end time of product A in the individual production plan data 61, the difference between the production end time of product B in the total production plan data 60 and the production end time of product B in the individual production plan data 61, etc. Note that it is also possible to consider the difference between the latest production end times among multiple products. Furthermore, (b-23) may be data relating to the difference that can be acquired from one or more production plan data created in the past. That is, (b-23) may be the difference between the production end time on the overall production plan data 60 belonging to each past production plan data and the production end time on the individual production plan data 61. Furthermore, (b-23) includes the difference between the value (theoretical value) of the production end time of the product on the overall production plan data 60 created in the past and the production end time (actual value) of each product when actually produced according to the same overall production plan data 60. In this case, too, it may be the difference for each product when multiple products are produced according to the overall production plan data 60. It may also be the difference between the production end time on the data for one or multiple production plan data (overall production plan data 60) created in the past and the actual production end time. (b-24) is information indicating whether or not a prescription change in the relevant individual production plan data 61 was actually possible when actual production was performed according to the individual production plan data 61 created in the past. For example, if the individual production plan data 61 includes an instruction to change the number of processes, but the number of processes could not actually be changed as instructed, data indicating that the number of processes could not be changed (prescription change) is input. Conversely, if the number of processes could be changed as instructed, data indicating this is input. This (b-24) may also be data acquired as the target of one or more individual production plan data 61. Furthermore, (b-24) may include one or more of information indicating whether a prescription change is possible for each period and information indicating whether a prescription change is possible for each combination of two types (products), or may be information indicating whether a prescription change is possible for two elements. (b-25) is information indicating whether transportation from each management warehouse to another management warehouse or to a consumer is possible. Note that (b-25) may include one or more of information indicating whether transportation is possible by type (product) and information indicating whether transportation is possible by transportation volume, or may be information indicating whether transportation is possible corresponding to two elements. The "upper limit of production volume within a specified period" in (b-26) is information indicating the maximum amount that can be produced at each production base and / or each production line when producing within a specified period. Also, the "lower limit of production volume within a specified period" is information indicating the minimum amount that must be produced when producing within a specified period at each production base and / or each production line. Also, (b-26) includes the upper and / or lower limits of the production volume within a specified period for each type (product). The "upper limit of production time within a specified period" in (b-27) is the longest and / or shortest production time when production is carried out at each production base and / or each manufacturing line within a specified period. Also, (b-27) includes the upper and / or lower limits of production time within a specified period for each type (product). (b-28) is the preparation cost incurred in the preparation stage of production, and is information (a collection of information) indicating the preparation cost for each product type to be produced at each production base and / or each manufacturing line. In this embodiment, (b-28) is data created based on the preparation cost based on the individual production plan data 61 created in the past, or the previously calculated objective variable (f-7) (described in detail later). That is, (b-28) is data obtained by feeding back the individual production plan data 61 created in the past, or the objective variable (f-7) calculated in the past. Note that (b-28) may have an initial value set at the start of operation, and thereafter use a value obtained by feeding back (f-7). Furthermore, (b-28) may be an actual measurement value of the preparation cost when production is actually carried out according to the individual production plan data 61. That is, it may be data obtained by feeding back the actual measurement value of the actual preparation cost. Furthermore, (b-28) may be a preparation cost for each group, similar to the above, by grouping similar products in advance. (b-29) is the preparation time incurred in the preparation stage of production, and is information (a collection of information) indicating the preparation time for each product type to be produced at each production base and / or each production line. In this embodiment, (b-29) is data created based on the preparation time based on the individual production plan data 61 created in the past, or the previously calculated objective variable (f-8) (described in detail later). That is, (b-29) is data obtained by feeding back the individual production plan data 61 created in the past, or the objective variable (f-8) calculated in the past. Note that (b-29) may have an initial value set at the start of operation, and thereafter use a value obtained by feeding back (f-8). Furthermore, (b-29) may be the actual measured value of the preparation cost when production is actually carried out according to the individual production plan data 61. That is, it may be data obtained by feeding back the actual measured value of the actual preparation time. Furthermore, (b-29) may be the preparation time for each group, similar to the above, after products are grouped together in advance. (b-30) is the recipe change cost for each product type at each production base and / or each production line. Specifically, (b-30) is a collection of information such as (first production base 10, production line X1, [previous product type: product A, next product type: product B], XXXX yen), (first production base 10, production line X1, [previous product type: product A, next product type: product C], XXXX yen). In other words, (b-30) is information (a collection of information) indicating the cost of switching each product type to another predetermined product type. In this embodiment, (b-30) is data created based on recipe change costs based on previously created individual production plan data 61 or a previously calculated objective variable (f-11) (described in detail below). In other words, (b-30) is data obtained by feeding back previously created individual production plan data 61 or a previously calculated objective variable (f-11). Note that (b-30) may have an initial value at the start of operation as the set value, and thereafter may be a value obtained by feeding back (f-11). Also, (b-30) may be an actual measurement value of the recipe change cost when production is actually carried out in accordance with the individual production plan data 61. In other words, it may be data obtained by feeding back the actual measurement value of the recipe change cost. Furthermore, as with the above, (b-30) may be the cost incurred when products are grouped in advance by similar type and when switching from a product belonging to one group to a product belonging to another group. (b-31) is the prescription change time for each product type at each production base and / or each production line. Specifically, (b-31) is a collection of information such as (first production base 10, production line X1, [previous product type: product A, next product type: product B], 1 day), (first production base 10, production line X1, [previous product type: product A, next product type: product C], 2 days). That is, (b-31) is information (a collection of information) indicating the time when each product type was switched to another predetermined product type. In this embodiment, (b-31) is data created based on the prescription change time based on previously created individual production plan data 61 or the previously calculated objective variable (f-12) (described in detail later). That is, (b-31) is data obtained by feeding back previously created individual production plan data 61 or the previously calculated objective variable (f-12). Note that (b-31) may have an initial value set at the start of operation, and thereafter may be a value obtained by feeding back (f-12). Also, (b-31) may be an actual measurement value of the recipe change time when production is actually performed according to the individual production plan data 61. In other words, it may be data obtained by feeding back the actual measurement value of the recipe change time. Furthermore, as with the above, (b-31) may be the time required to switch from a product belonging to one group to a product belonging to another group, by grouping products of similar types in advance. (b-32) is information indicating the product type for which a prescription change is recommended as a priority for cost reduction at each production site and / or each production line, and the cost reduction achieved by replacing a specified product type with the recommended product type. Specifically, (b-32) is a collection of information such as (first production site 10, production line X1, [recommended product type: product a, substitutable product type: product A], XXXX yen), (second production site 11, production line Y1, [recommended product type: product b, substitutable product type: product B], YYYY yen). That is, the first example above is data indicating that, when changing the prescription for the production of product A on the production line X1 of the first production site 10, by replacing product A with product a, costs can be reduced by XXXX yen. Similarly, the second example above is data indicating that, when changing the prescription for the production of product B on the production line Y1 of the second production site 11, by replacing product B with product b, costs can be reduced by YYYY yen. Similarly to the above, (b-32) may be used to group products into similar groups in advance. In other words, it may be used as information indicating a product group for which a recipe change is recommended as a priority, and the cost reduction that will occur if a product group is changed to that product group instead of a specified product group. (b-33) is information indicating the product type for which a prescription change is recommended as a priority in order to reduce the time required for a prescription change at each production site and / or each production line, and the time that will be reduced if a specific product type is changed to the recommended product type. Specifically, (b-33) is a collection of information such as (first production site 10, production line X1, [recommended product type: product a, substitutable product type: product A], 5 hours), (second production site 11, production line Y1, [recommended product type: product b, substitutable product type: product B], 1 day). In other words, the first example above is data indicating that, when a prescription change is made for the production of product type A at production line X1 of the first production site 10, the time required for production completion can be reduced by 5 hours by changing the prescription to product type a instead of product type A. Similarly, the second example above is data showing that when changing the recipe for the production of product type B on manufacturing line Y1 at second production site 11, changing the recipe to product type b instead of product type B can reduce the time until production is completed by one day. Also, as with the above, (b-33) may be grouped in advance by products of similar types. In other words, it may be information showing a product type group for which a recipe change is recommended as a priority, and the cost reduction that will occur when a specified product type group is changed to the recommended product type group. (b-34) is information (a collection of information) indicating the preparation cost for each product type to be produced at each production base and / or each production line, and is information (a collection of information) indicating the preparation cost for each product type for each period. Specifically, (b-34) is a collection of information such as (first production base 10, production line X1, product type A, first week of January, XXXX yen), (second production base 11, production line Y1, product type A, second week of January, YYYY yen). That is, the first example above is data indicating that the preparation cost for producing product type A in the first week of January on production line X1 of the first production base 10 is XXXX yen. In other words, (b-34) is a collection of information indicating the preparation cost for producing a specific product type at a specific location for a specific period. This (b-34) may be information that associates the fluctuation value of the preparation cost for each period with the information indicated in (b-28) above. In this embodiment, (b-34) is data created based on the preparation costs by period based on the individual production plan data 61 created in the past, or the objective variable (f-9) calculated in the past (details will be described later). That is, (b-34) is data obtained by feeding back the individual production plan data 61 created in the past, or the objective variable (f-9) calculated in the past. Note that (b-34) may have an initial value set at the start of operation, and thereafter use values ​​obtained by feeding back (f-9). Also, (b-34) may be an actual measurement value of the preparation costs by period when production is actually carried out according to the individual production plan data 61. That is, it may be data obtained by feeding back the actual measurement value of the preparation costs by period. Furthermore, as in the above, (b-34) may be a preparation cost by period for each group, which is obtained by grouping similar types of products in advance. (b-35) is information (a collection of information) indicating the preparation time for each product type to be produced at each production base and / or each production line, and is information (a collection of information) indicating the preparation time for each product type for each period. Specifically, (b-35) is a collection of information such as (first production base 10, production line X1, product type A, first week of January, 5 hours), (second production base 11, production line Y1, product type A, first week of May, 6 hours). In other words, (b-35) is a collection of information indicating the preparation time required to produce a specific product type at a specific location in a specific period. This (b-35) may be information obtained by associating the information indicated in (b-29) with a variation in the preparation time for each period. (b-35) in this embodiment is also data obtained by feeding back previously created individual production plan data 61 or a previously calculated objective variable (f-10). Note that (b-35) may have an initial value set at the start of operation, and thereafter may be a value obtained by feeding back (f-10). Also, (b-35) may be an actual measurement value of preparation time for each period when production is actually carried out in accordance with the individual production plan data 61. In other words, it may be data obtained by feeding back the actual measurement value of preparation time for each period. Furthermore, as with the above, (b-35) may be used to group products of similar type in advance, and use the preparation cost for each group by period. (b-36) is the prescription change cost for each product type by period at each production base and / or each production line. Specifically, (b-36) is a collection of information such as (first production base 10, production line X1, [previous product type: product type A, next product type: product type B], first week of January, XXXX yen). This (b-36) may be information that associates the information shown in (b-30) with the fluctuation value of the prescription change cost for each period. In other words, (b-36) is information (a collection of information) that indicates the cost for each product type by period when switching to another predetermined product type. In this embodiment, (b-36) is data created based on prescription change costs based on previously created individual production plan data 61 or based on previously calculated objective variable (f-13) (described in detail below). In other words, (b-36) is data that incorporates previously created individual production plan data 61 or previously calculated objective variable (f-13) as feedback. Note that (b-36) may have an initial value at the start of operation as the set value, and thereafter may be a value obtained by feeding back (f-13). Also, (b-36) may be an actual measurement value of the recipe change cost when production is actually carried out in accordance with the individual production plan data 61. In other words, it may be data obtained by feeding back the actual measurement value of the recipe change cost. Furthermore, as with the above, (b-36) may be the cost incurred when products are grouped in advance into groups of similar type and when switching from a product belonging to one group to a product belonging to another group. (b-37) is the prescription change time for each product type at each production base and / or each production line by period. Specifically, (b-37) is a collection of information such as (first production base 10, production line X1, [previous product type: product type A, next product type: product type B], first week of January, 1st day). This (b-37) may be information obtained by associating the information shown in (b-31) with a fluctuation value of the prescription change time for each period. In other words, (b-37) is information (a collection of information) indicating the time required for each product type to be switched to another predetermined product type by period. In this embodiment, (b-37) is data created based on the prescription change time based on previously created individual production plan data 61 or the previously calculated objective variable (f-14) (described in detail later). In other words, (b-37) is data obtained by feeding back the previously created individual production plan data 61 or the previously calculated objective variable (f-14). Note that (b-37) may have an initial value set at the start of operation, and thereafter may be a value obtained by feeding back (f-14). Also, (b-37) may be an actual measurement value of the recipe change time when production is actually performed according to the individual production plan data 61. In other words, it may be data obtained by feeding back the actual measurement value of the recipe change time. Furthermore, as with the above, (b-37) may be the time required to switch from a product belonging to one group to a product belonging to another group, with products being grouped in advance by similar type. (b-38) includes information indicating the degree of similarity with a combination of varieties (products) that have been produced simultaneously in the past when production was carried out according to the individual production plan data 61, and information relating to the time when the simultaneous production was carried out. In the production planning system 1 of this embodiment, a similarity to other combinations of product varieties is set in advance for each combination of product varieties. In detail, for example, the similarity between the combination of product A and product B and the combination of product a and product b is 10, and the similarity between the combination of product c and product d is 5. Similarly, the similarity between the combination of product a and product b and the combination of product c and product d is 3. In other words, the similarity is information that can be referenced to check the degree of similarity, and may be, for example, a value or rank that is set so that the more similar the combinations of product varieties are, the higher (or lower) the value or rank. The information indicating the combination of products that have been simultaneously produced in the past is associated with the production time. In this case, if the same combination of products has been produced multiple times in the past, multiple production times may be associated. Furthermore, (b-38) includes information indicating the recommendation level for simultaneous production of a combination of product varieties (products) that has a track record of simultaneous production, and this information is associated with information indicating combinations of products that have been simultaneously produced in the past. In the production planning system 1 of this embodiment, a recommendation level for simultaneous production is preset for each combination of product varieties (products) that has a track record of simultaneous production. In detail, for example, the recommendation level for the combination of product A and product B may be 5, and the recommendation level for product a and product b may be 4. In other words, the recommendation level is information that can be referenced to confirm the recommendation level for simultaneous production. For example, the recommendation level may be a value or rank that is set so that it increases (or decreases) as the recommendation level increases. This recommendation level is set based on the results of simultaneous production of a specified combination of product varieties or past simulations. For example, if simultaneous production of a specified combination of product varieties saves more time than planned, a recommendation level is assigned according to the time saved. That is, by referring to (b-38), it is possible to determine whether the combination of multiple products (varieties) to be produced in the overall production plan data 60 to be created is highly similar to combinations that have been produced simultaneously at the same time in the past. Note that a highly similar combination here includes the same combination as a combination that has been produced simultaneously at the same time in the past. If the combination is highly similar, it is possible to determine whether the combination of multiple products (varieties) to be produced this time is highly recommended for simultaneous production by referring to the recommendation level of similar past combinations. Note that "the same period in the past (or approximately the same period)" here refers to a period in which the dates are in different years but the same month, such as the same month one year ago, or a period in which the start and end dates are in different years but the same month and date, or approximately the same period. Also, "approximately the same period" allows for a difference of several days. In other words, "the same period in the past (or approximately the same period)" here refers to a period in months or days. In this embodiment, (b-38) is data created based on (f-15) (details will be described later), which is a previously calculated objective variable, i.e., data that has been fed back using (f-15). (b-39) includes a group of information (data) indicating the production volume by product type (product) and period obtained from the overall production plan data 60 that has been used in past production. For example, the production volume of product type A from 20XX / XX / XX to 20XX / XX / XX is XX tons, and the production volume of product type B from 20XX / XX / XX to 20XX / XX / XX is XX tons. It also includes the number of past overall production plan data 60 from which information was obtained. In other words, (b-39) is information that, by referencing it, can identify the production volume values ​​for each product type during the same period (or approximately the same period) in the past and the average production volume for each product type, based on the second period (described in detail below) that is the target of the overall production plan data 60 to be created. Note that the "same period (or approximately the same period) in the past" here refers to a period in months or days.

[0049] The constraints used to solve the optimization problem in the first optimization unit 46 can be changed as appropriate depending on explanatory variable data, etc., but in this embodiment, the above-mentioned (b-5) to (b-11), (b-17) to (b-19), and (b-23) to (b-27) are used.

[0050] The objective variables (first objective variable data) calculated by the first optimization unit 46 include the following (c-1) and (c-2). (c-1) Production volume of each production site and / or each production line (c-2) Context of production volume

[0051] The "production volume" in (c-1) is the volume of product ordered (requested production) from each production base and / or each manufacturing line, in other words, the order for the product. (c-1) may include one or more of the production volume of product by type (product) and the production volume of product by period, or it may be the production volume of product corresponding to two elements. (c-2) is the order of each production quantity (order), and is information that indicates the order of each order (execution order or priority order), for example, (1: Order C, 2: Order B, ...). In other words, in the above example, the production of the product related to Order C will start, followed by the production of the product related to Order B, ... and so on, as the orders are executed (processed).

[0052] The overall plan creation unit 47 is a component that creates overall production plan data 60 using the objective variable data calculated and created by the first optimization unit 46. The overall production plan data 60, which will be described in detail later, is production plan data that summarizes schedules for production, transportation, shipping, etc. at each base from production at the first production base 10 to shipping.

[0053] As shown in FIG. 5, the second input section 48 is a section for inputting second explanatory variable data. The second input unit 48 is capable of inputting the input second explanatory variable data to the second optimization unit 49. The second input unit 48 may acquire part of the second explanatory variable data from the data accumulation unit 52 and input it to the second optimization unit 49.

[0054] The second optimization unit 49 is a part that calculates the objective variables from the second explanatory variable data input to the second input unit 48 by solving an optimization problem whose objective function is to minimize the following (d-1) and (d-2) while satisfying the second constraint condition, and creates the second objective variable data. (d-1) The difference between the latest time and the end of production in the specified order period (d-2) Prescription change time

[0055] The "latest time in the order specification period" in (d-1) is the latest production end time among the production end times of the products in the overall production plan data. Also, the "production end time" is the actual production end time (measured value) of each product when it is produced at the production base according to the overall production plan data. In other words, (d-1) is the difference between the latest production end time (theoretical value) among the production end times of the products in the overall production plan data 60 and the actual production end time (measured value) of each product when the product is produced in accordance with the overall production plan data. Naturally, this "difference" applies to the same production plan and the same production base. Furthermore, the production planning system 1 of this embodiment calculates the objective variable by solving an optimization problem whose objective function is to minimize the largest difference between the theoretical and actual values ​​of the production end time at each production base when the product is produced at that production base. (d-2) is the time required to change the recipe after the production of a specified product, such as switching the type (variety) of the product, changing the ratio of raw materials (ingredients), or changing the number of processes. That is, the second optimization unit 49 calculates the objective variables by solving an optimization problem whose objective functions are the largest difference between the production end time of a product at one production base in the overall production plan data 60 and the production end time of each product when produced at the same production base in accordance with the overall production plan data 60, and minimizing the recipe change time at the same production base, and creates second objective variable data. Note that the optimization methods that can be used to solve the optimization problem are the same as those described above, and redundant detailed explanations will be omitted.

[0056] Furthermore, the second optimization unit 49 may be configured to calculate the second objective variable data by solving an optimization problem in which the objective function is to minimize the following (d-3) in addition to the above (d-1) and (d-2): (d-3) Similarity with past plans

[0057] The "similarity with past plans" in (d-3) refers to the similarity with individual production plan data 61 (described in detail later) created in the past, and the higher the similarity, the lower the preset setting value. Here, the "similarity to the past plan" is evaluated based on the degree of approximation to the past individual production plan data 61 for each preset item. Similarity and approximation are the same as those explained in (a-12) above, so a duplicate explanation will be omitted. In other words, the production planning system 1 calculates the second objective variable data so that the content is closer to the second objective variable data used when creating the individual production plan data 61 created in the past, by using the minimization of (d-3) as the objective function.

[0058] The second explanatory variable data input to the second optimization unit 49 from the second input unit 48 includes one or more of the following (e-1) to (e-19), and in this embodiment includes all of (e-1) to (e-19). (e-1) Production volume at each production site and / or each production line (e-2) Production sequence (e-3) Retention time for each type (product) at each production site and / or each production line (e-4) Minimum production interval time for each type (product) at each production site and / or each production line (e-5) Stop time of each production site and / or each production line (e-6) Maximum simultaneous production limit between series at each production site (e-7) Maximum simultaneous production of the same color between series at each production site (e-8) Curing time for each type (product) at each production site and / or each production line (e-9) Maximum simultaneous curing capacity between series at each production site (e-10) Maximum limit of simultaneous same-color curing between series at each production base (e-11) Filling time by type (product) at each production site and / or each production line (e-12) Maximum simultaneous filling limit between series at each production site (e-13) Maximum simultaneous filling of the same color between series at each production base (e-14) Minimum residence time after filling by type (product) at each production site and / or each manufacturing line (e-15) Recipe change time for each product combination when switching from one product type to another at each production site and / or each production line (e-16) Possibility of formula change for each product combination at each production site and / or each production line, and formula change rank (e-17) Maximum number of recipe changes at each production site and / or each manufacturing line (e-18) The time required to change the recipe between products at each production site and / or each manufacturing line (e-19) Production completion time of each production site and / or each production line (e-20) Production volume by type (product) and time based on past individual production plan data 61, and the number of target individual production plan data 61

[0059] The above (e-1) is the production volume when production was actually carried out in the past at each production base and / or each manufacturing line in accordance with the overall production plan data 60. In other words, (e-1) is the production volume (order) of the product that was ordered (requested to be produced) in the past. In this embodiment, (e-1) is a set of information related to past production volume. In detail, (e-1) may be a collection of multiple sets of information that associate information indicating a production base, information indicating a production line, information indicating a type (product), information indicating a production period (information specifying the time when production ended), and information indicating a production volume, for example, (second production base 11, production line Y1, type x, up to the first period, 3 tons). The above (e-2) is the order of production volumes (orders) when actual production was carried out in the past at each production base and / or each manufacturing line in accordance with the overall production plan data 60. In detail, (e-2) is information indicating the actual order of production (execution order) of each order, for example, (1: Order C, 2: Order B, ...). In this embodiment, the "pre- and post-production waiting time" in (e-3) above is the minimum waiting time for each type (product) after production until it is used in the next process. In this embodiment, it is a collection of information related to the minimum waiting time. In detail, (e-3) may be a collection of multiple sets of information that associate information indicating a production base, information indicating a production line, information indicating a type (product), and information indicating the minimum waiting time, for example, such as (first production base 10, production line X3, type C, 4 hours). The "minimum production interval time" in (e-4) above is the minimum time that must be allowed after a certain product type has been produced (manufactured) before that product type can be produced again. In this embodiment, this is a collection of information related to the minimum production interval time. In detail, (e-4) may be a collection of multiple sets of information that associate information indicating a production base, information indicating a production line, information indicating a product type (product), and information indicating the minimum production interval time, for example, (third production base 12, production line Z1, product type A, 12 hours). The above (e-5) is information indicating the time (period) when each production base and / or each production line is stopped, and in this embodiment, it is a collection of information related to the stop time of the production base and / or production line. In detail, (e-5) may be a collection of multiple sets of information that associate information indicating a production base, information indicating a production line, and information indicating the stop period (information related to the stop time), for example, like (first production base 10, production line X1, 24th hour to 36th hour). The above (e-6) is the upper limit of simultaneous production for multiple lines. Here, a "line" refers to one system that progresses through each process from raw materials through intermediate products to the final product, and multiple lines refer to multiple lines. In this embodiment, the above (e-6) is a collection of information regarding the upper limit of simultaneous production for multiple lines. In detail, (e-6) may be a collection of multiple sets of information that associate information indicating a production site, information indicating the target production line (multiple production lines), and information indicating the upper limit of simultaneous production for multiple lines, such as (first production site 10, [production line X1, production line X1], line 1), (first production site 10, [production line X3, production line X4, production line X5], line 2). The production planning system 1 of this embodiment is designed to produce multiple types of foam molded products and includes the upper limit of simultaneous production (upper limit of simultaneous foaming line) between lines (foaming line) whose final products are foam molded products. In this embodiment, the above (e-7) is information regarding the upper limit of simultaneous production of the same color in multiple lines. In detail, (e-7) may be a collection of multiple sets of information that associate information indicating a production base, information indicating a target production line (multiple production lines), information indicating the colors of the products to be simultaneously produced, and information indicating the upper limit of simultaneous production in multiple lines, such as (first production base 10, [production line X1, production line X1], black, 1st line), (first production base 10, [production line X3, production line X4, production line X5], white, 2nd line). The above (e-8) is the time required for the curing process when producing foam-molded products. The above (e-9) is the upper limit of the number of curing steps that can be carried out simultaneously when multiple foaming series are carried out simultaneously. The above (e-10) is the upper limit of the number of curing processes that can be simultaneously performed when multiple foaming series are simultaneously carried out to produce products of the same color. The above (e-11) is the time required to fill the raw material (or material) into the production equipment (including the mold) when producing the foam-molded product. The above (e-12) is the upper limit of the number of filling steps (steps for filling raw materials, etc.) that can be carried out simultaneously when multiple foaming series are carried out simultaneously. The above (e-13) is the upper limit of the number of filling processes that can be carried out simultaneously when multiple foaming series are carried out simultaneously to produce products of the same color. The "minimum residence time after filling" in (e-14) above is the minimum waiting time after filling until shipping, and is a time including inspection time, etc. In this embodiment, it is a collection of information related to the minimum residence time after filling for multiple lines. In detail, (e-14) may be a collection of multiple sets of information that associate information indicating a production base, information indicating a production line, information indicating a type (product), and information indicating the minimum residence time after filling, for example, (first production base 10, production line X1, type A, 2 days). The above (e-15) is a set of information related to prescription change times. In detail, (e-15) may be a collection of a plurality of sets of information that associate information indicating a production base, information indicating a production line, a combination of types (products), information indicating the order of prescription change for the types, and information indicating prescription change times, for example, (first production base 10, production line X1, [previous type: type A, next type: type A], 2 days). The above (e-16) is information indicating whether a prescription change from a specific product type to another product type is not possible, and information indicating the prescription change rank when the prescription change is possible. The prescription change rank is a rank determined in advance according to the work time (and / or cost) required for the prescription change. For example, it may be S rank, A rank, B rank, etc., and the higher (lower) the rank, the more work time (cost) the prescription change requires. The above (e-16) may be a collection of information regarding whether a prescription change is possible and the prescription change rank. In detail, (e-16) may be a collection of multiple sets of information associating information indicating a production base, information indicating a production line, a combination of products (products), information indicating the order of product type prescription changes, and information indicating whether a prescription change is possible and the prescription change rank (if a prescription change rank is available, the prescription can be changed). In this embodiment, the above (e-17) may include one or more of the maximum number of prescription changes by prescription change rank, the maximum number of prescription changes by period, and the maximum number of prescription changes by product type (product) combination, or may be the maximum number of prescription changes corresponding to two or more elements. The above (e-17) may be a collection of information related to the maximum number of prescription changes. In detail, (e-17) may be a collection of multiple sets of information that associate information indicating a production base, information indicating a production line, a product type (product) combination, information indicating a prescription change rank, information indicating a period, and information indicating the maximum number of prescription changes, such as (first production base 10, production line X1, S rank, first half of the month, 5 times). The above (e-18) is the time (actual measured value) required to change the recipe obtained when actual production was carried out in the past at each production base and / or each manufacturing line in accordance with the overall production plan data 60, and is the recipe change time for each type of change. The above (e-19) is the production completion time (actual measurement value) of each product when production was actually carried out in the past at each production base and / or each manufacturing line according to the overall production plan data 60. The above (e-20) includes a group of information (data) indicating the type (product) and production volume by time acquired from the individual production plan data 61 that has been used in past production. For example, the production volume of type A from XX:XX on XX / XX / 20XX to XX:XX on XX / XX / 20XX is XX tons. Note that the time here is measured in minutes. It also includes the number of past individual production plan data 61 from which information was acquired. In other words, (e-20) is information that, by referencing it, can identify the production volume values ​​for each type of product at the same time (or approximately the same time) in the past and the average production volume for each type of product, based on the third period (described in detail below) that the individual production plan data 61 to be created targets. Note that the "same time (or approximately the same time) in the past" here refers to a time measured in minutes. Furthermore, the "approximately the same time" allows for a difference of several minutes.

[0060] The constraints used to solve the optimization problem in the second optimization unit 49 can be changed as appropriate depending on explanatory variable data, etc., but in this embodiment, the above-mentioned (e-2) to (e-10), (e-12) to (e-14), (e-16), and (e-17) are used.

[0061] The objective variables (second objective variable data) calculated by the second optimization unit 49 include the following (f-1) to (f-6). (f-1) Production start time and production end time at each production base and / or each production line (f-2) Curing start time and curing end time at each production site and / or each manufacturing line (f-3) Filling start time and filling end time at each production site and / or each production line (f-4) Relaxation time for maximum operating hours at each production site and / or each manufacturing line (f-5) Possibility of simultaneous production at each production site and / or each manufacturing line (f-6) Production sequence at each production site and / or each manufacturing line

[0062] The above (f-1) is at least one of the production start time by order (for each product) and the production end time by order, and in this embodiment, it is both. The above (f-2) is at least one of the start time of the curing process for each order and the end time of the curing process for each order, and in this embodiment, it is both. The above (f-3) is at least one of the start time of the filling process for each order and the end time of the filling process for each order, and in this embodiment, it is both. In this embodiment, the above (f-4) is the relaxation time of the maximum operating time by period. This "relaxation time of the maximum operating time" is the difference between the latest time of the specified period of the order to which the product belongs in the overall production plan data 60 (details will be described later) and the production end time of the same product in the individual production plan data 61 (details will be described later) related to the same production plan. The above (f-5) may include one or more of information indicating whether simultaneous production is possible for each period, information indicating whether simultaneous production is possible for each combination of product types, or information indicating whether simultaneous production is possible for two elements. In this embodiment, it is information indicating whether simultaneous production is possible for two elements. "Information indicating whether simultaneous production is possible" is information indicating whether a prescription can be changed from one specified product type (product) to another product type (product). The above (f-6) is the order in which products are produced at each production base and / or each manufacturing line (order execution order).

[0063] The objective variables (second objective variable data) calculated by the second optimization unit 49 may include the following (f-7) to (f-15).

[0064] (f-7) Preparation costs for each production site and / or each production line by type (product) (f-8) Preparation time for each production site and / or each production line by type (product) (f-9) Preparation costs by type (product) and period for each production site and / or each production line (f-10) Preparation time by type (product) and period for each production site and / or each production line (f-11) Recipe change costs by type (product) of each production site and / or each manufacturing line (f-12) Recipe change time by type (product) at each production site and / or each production line (f-13) Recipe change costs by type (product) and period for each production site and / or each manufacturing line (f-14) Recipe change time by type (product) and period for each production site and / or each production line (f-15) Similarity with the combination of varieties (products) that have been produced simultaneously by period at each production base and / or each production line, and the degree of recommendation for simultaneous production

[0065] The above (f-7), like the above (b-28), is the preparation cost incurred in the preparation stage of production, and is information (a collection of information) indicating the preparation cost for each type of product to be produced at each production base and / or each manufacturing line. The above (f-8), like the above (b-29), is the preparation time that occurs in the preparation stage of production, and is information (a collection of information) that indicates the preparation time for each type of product to be produced at each production base and / or each manufacturing line. The above (f-9), like the above (b-34), is information (a collection of information) showing the preparation costs for each type of product to be produced at each production base and / or each manufacturing line, and is information (a collection of information) showing the preparation costs for each type of product for each period. The above (f-10), like the above (b-35), is information (a collection of information) indicating the preparation time for each type of product to be produced at each production base and / or each production line, and is information (a collection of information) indicating the preparation time for each type of product for each period. The above (f-11), like the above (b-30), is the recipe change cost for each product type at each production base and / or each production line. The above (f-12), like the above (b-31), is the recipe change time for each product type at each production base and / or each production line. The above (f-13), like the above (b-36), is the recipe change cost by period for each product type at the production base and / or each production line. The above (f-14), like the above (b-37), is the recipe change time by period for each product type at each production base and / or each production line. The above (f-15) includes information indicating the degree of similarity between the combination of varieties to be simultaneously produced in the individual production plan data 61 to be created and a combination of varieties that has a track record of being simultaneously produced at the same time (or approximately the same time) in the past. Furthermore, a recommendation degree for simultaneous production is associated with the information indicating the combination of varieties to be simultaneously produced in the individual production plan data 61 to be created. Note that if there is no combination of varieties with high similarity that was simultaneously produced at the same time (or approximately the same time) in the past, the recommendation degree for simultaneous production will be a default value. Note that the terms "at the same time (or approximately the same time)," "similarity," and "recommendation degree for simultaneous production" here are the same as those explained in (b-38) above, so repeated explanation will be omitted.

[0066] The output unit 51 is a part that outputs the production plan data (total production plan data 60, individual production plan data 61) created by the overall plan creation unit 47 and the individual plan creation unit 50 to terminals at each base.

[0067] The data accumulation unit 52 is a part that stores (stores) past and present first explanatory variable data, first constraint condition data, first objective variable data, second explanatory variable data, second constraint condition data, second objective variable data, objective function data, and production plan data (total production plan data 60, individual production plan data 61).

[0068] Next, the production planning operation of the production planning system 1 of this embodiment will be described.

[0069] In the production planning operation, based on a production request for the product 100 from a consumer, some or all of the explanatory variable data (first explanatory variable data, second explanatory variable data) is input to the input units (first input unit 45, second input unit 48) of the management computer 16. That is, some or all of the first explanatory variable data is input to the first input unit 45, and simultaneously or subsequently, some or all of the second explanatory variable data is input to the second input unit 48.

[0070] Furthermore, when part or all of the first explanatory variable data is input to the first input unit 45, the production planning system 1 acquires the remaining part of the first explanatory variable data from the data accumulation unit 52 at the same time as or around the same time. The first explanatory variable data is then input to a first optimization unit 46. The first optimization unit 46 solves an optimization problem using the input first explanatory variable data, with the objective function being to minimize the cost while satisfying the first constraint condition, to calculate a first objective variable, and creates first objective variable data. Once the first objective variable data has been created by the first optimization unit 46, an overall plan creation unit 47 creates overall production plan data 60 using the first objective variable data.

[0071] As shown in Fig. 6, the overall production plan data 60 is data indicating a production plan including the production end time of each product at each production base (first production base 10 to fourth production base 13). In detail, the overall production plan data 60 is data indicating the production start time of each product at each production base (the start time of the first process among all processes involved in the production of that product), the production end time of each product (the end time of all processes involved in the production of that product), the storage period of the product in the management warehouse at each base, the start and end times of prescription change work (work to switch product types), and the schedule of each process (each task) necessary for production, such as transportation or shipping, and is data indicating the schedule of each process in minutes. In other words, the overall production plan data 60 can be said to be data expressing the schedule of each of the above-mentioned processes (data that allows the schedule of each process to be identified).

[0072] In this embodiment, of the production plan for a predetermined period (one year in this embodiment, also referred to as the first period hereinafter), the overall production plan data 60 is output for a portion corresponding to a predetermined period (one month in this embodiment, also referred to as the second period hereinafter) that falls within the first period. Therefore, the overall production plan data 60 in this embodiment is also data that indicates (expresses) a monthly plan.

[0073] 6 indicates, for example, that production of intermediate product A1 is scheduled to start at 11:10 on January 1st at the first production base 10, to end at 12:00 on January 2nd, and that the produced intermediate product A1 is scheduled to be stored in the first management warehouse 21 until 11:00 on January 3rd. It also indicates that the intermediate product A1 is scheduled to be transported to the second production base 11 together with intermediate products A2 and A3 that are produced separately. It also indicates that work to change the recipe (work to switch the product type) is to be performed at the first production base 10, and that intermediate product B1 is scheduled to be produced. Similarly, at other bases, for example, it is shown that at the third production base 12, production of the intermediate product β1 will start from 14:30 on January 3rd, end at midnight on January 4th, and the intermediate product β1 produced until noon on January 5th will be stored in the third management warehouse 29. In addition, it is shown that at the shipping base, shipping work for the final product will be carried out from 22:30 on January 7th to 3:00 on January 8th (the end time is not shown for convenience of drawing). Detailed explanation of other parts of the overall production plan data 60 will be omitted.

[0074] Furthermore, when part or all of the second explanatory variable data is input to the second input unit 48, the production planning system 1 acquires the remaining part of the second explanatory variable data from the data accumulation unit 52 at the same time as or around the same time. The second explanatory variable data is then input to the second optimization unit 49. The second optimization unit 49 solves an optimization problem using the input second explanatory variable data, with the objective function being to minimize the above (d-1) and (d-2) while satisfying the above second constraint condition, to calculate a second objective variable, and creates second objective variable data. Once the second objective variable data has been created by the second optimization unit 49, the overall plan creation unit 47 creates overall production plan data 60 using the second objective variable data.

[0075] In this embodiment, when creating production plan data (total production plan data 60, individual production plan data 61) for one production plan, the total production plan data 60 is created first, and the created total production plan data 60 (information indicated by the total production plan data 60) is used as part of the second explanatory variable data. That is, when creating production plan data, the total production plan data 60 is created first, followed by the individual production plan data 61. Also, individual production plan data 61 is created for each production base. That is, although detailed illustration is omitted, for example, in this embodiment, four individual production plan data 61 are created, consisting of individual production plan data 61 for the first production base 10, ..., and individual production plan data 61 for the fourth production base 13.

[0076] 7, the individual production plan data 61 is output for a portion corresponding to a period of a predetermined length within the second period (one week in this embodiment, hereinafter also referred to as the third period). In other words, the individual production plan data 61 corresponds to the same production plan as the overall production plan data 60, and covers the third period (January 1 to January 7), which is part of the second period (January 1 to January 31 in FIG. 6) covered by the overall production plan data 60. That is, in this embodiment, the third period covered by the individual production plan data 61 has the same start date (start time) as, but is shorter than, the second period covered by the paired overall production plan data 60. In other words, the individual production plan data 61 is also data indicating a detailed plan (representing a detailed plan) that is a detailed version of a portion of the monthly plan.

[0077] The individual production plan data 61 is data including the production sequence and production start time of products to be produced at the target production base (first production base 10 in FIG. 7). In other words, the individual production plan data 61 is data indicating a production plan, and is data indicating the contents of a plan that is more detailed than the overall production plan data 60. In detail, it is data that shows (expresses) schedules such as the start and end times of each process involved in the production of each product, the manufacturing line (place of execution) that carries out each process, the order in which each order (production) is executed, and the start and end times of any work to change the recipe (the work of switching product varieties), and it is data that shows the scheduled times in minutes.

[0078] The individual production plan data 61 shown in FIG. 7 indicates that the first process of the process for producing an intermediate product A1 based on order C is scheduled to start at 11:10 on January 1st on the production line 1. Similarly, it is shown that the first process of the process for producing intermediate product A2 is scheduled to start at 9:30 PM on January 1st on production line 2. It also shows that the production of this intermediate product A1 is based on order A. Similarly, it is also indicated that the second process of the process for producing intermediate product A1 based on order C is scheduled to start on manufacturing line 3 at 1:10 on January 2nd. It also shows that the first process of the process for producing intermediate product A3 based on order B is scheduled to start on production line 1 at 1:10 on January 2nd.

[0079] That is, the individual production plan data 61 indicates the order execution sequence (production sequence) at the first production base 10, and more specifically, indicates that production will begin in the order of order C, order A, and order B. Furthermore, the individual production plan data 61 indicates the execution sequence (production sequence) of each process (each job), and it can be seen that the processes will be executed in the following order: first process in the production of intermediate product A1, first process in the production of intermediate product A2, second process in the production of intermediate product A1, first process in the production of intermediate product A3, and so on. Note that detailed explanations of other parts of the individual production plan data 61 will be omitted.

[0080] Once the overall production plan data 60 and the individual production plan data 61 are created, they are sent from the output unit 51 to each base. Upon receiving the production plan data (overall production plan data 60, individual production plan data 61), each base produces, stores, transports, and ships various products in accordance with the production plan data. In detail, each production base (first production base 10 to fourth production base 13) produces various products in accordance with the individual production plan data 61. In addition, each base stores, transports, and ships in accordance with the production plan data.

[0081] Here, the production planning system 1 of this embodiment executes a production plan update operation to update the production plan data (total production plan data 60, individual production plan data 61) every time a predetermined period (one week, which is the third period in this embodiment) elapses.

[0082] To explain in more detail, for example, production of each product is carried out in accordance with the overall production plan data 60 and individual production plan data 61 described above for the period from January 1st to January 7th. At this time, each base acquires actual measured values ​​relative to the theoretical values ​​of the production plan data. For example, when intermediate product A1 is produced, if the production end time scheduled in the production plan data is 12:00 on January 2nd, but the actual production end time is 15:30 on January 2nd, the scheduled production end time becomes the theoretical value, and the actual production end time becomes the corresponding actual measured value. Furthermore, the difference between the theoretical value and the actual measured value is 3 hours and 30 minutes. At this time, information is obtained from the difference between the scheduled production end time (period) and the actual production end time (period) regarding the time that exceeds the schedule (the time that exceeds the schedule when the actual production end time is delayed, etc.) and the remaining time (the remaining time when the actual production end time is brought forward, etc.).

[0083] Then, information relating to the acquired actual measurement values ​​is input to the input unit (first input unit 45 and / or second input unit 48) to create overall production plan data 60 and individual production plan data 61. At this time, the production planning system 1 of this embodiment creates the overall production plan data 60 and then the individual production plan data 61 in that order. More specifically, overall production plan data 60 (details not shown) covering the period from January 8 to February 7 and individual production plan data 61 covering the period from January 8 to January 14 are created. Then, the newly created overall production plan data 60 and individual production plan data 61 are sent to each base, and the management computer 16 and / or the production plan data at each base are updated.

[0084] In other words, the production planning system 1 sets the new second period to the period that is the same length as the second period (January 1st to January 31st) that was the subject of the overall production plan data 60 created the previous time, minus the period that has elapsed (January 1st to January 7th), and adds a period that is consecutive to the previous second period (February 1st to February 7th), and creates the overall production plan data 60 for the new second period. Similarly, the production planning system 1 updates the production plan data every time a predetermined period (the third period, which is one week) elapses.

[0085] As a result, the production planning system 1 of this embodiment creates more accurate (more production efficient) production plan data every time a production plan update operation is executed. To explain in more detail, for example, in the overall production plan data 60 shown in Figure 6, if the production start time of the first intermediate product A1 or the production start time of intermediate product A2 is delayed, it is thought that it will be possible to eliminate or reduce the storage time in the management warehouse. In other words, when creating production plan data, by more appropriately setting (adjusting forward or backward as appropriate) the production start time and production end time of each product, it will be possible to create more efficient production plan data with less waste. In addition, it is thought that production efficiency can be improved by planning a production period (the period from the production start time to the production end time) that has no or little overtime or surplus time. As the production planning system 1 of this embodiment continues to operate, it accumulates data that can be used as explanatory variables, making it possible to create more accurate production planning data with less difference between the plan and the actual situation.

[0086] The above-described embodiment shows an example in which the second period when the first production plan data is created is from January 1st to January 31st, and the second period when the second production plan data is created is from January 8th to February 7th, and all of the multiple second periods are the same length (one month, regardless of the number of days). However, for example, the second period when the first production plan data is created may be one month (e.g., from January 1 to January 31), and the second period when the first production plan data is created may be two months (e.g., from January 8 to March 7). That is, the multiple second periods may all be the same length, or may be periods of different lengths, or may include two or more periods of the same length and periods of different lengths. When the multiple second periods include two or more periods (second periods) of different lengths, it is conceivable that the third period is shorter than the shortest period (second period).

[0087] The production planning system 1 of this embodiment may use minimization of (a-11) and (a-12) as an objective function when calculating the first objective variable data, and may include the above-mentioned (b-28) to (b-39) in the first explanatory variable data. In addition, the production planning system 1 may use minimization of (d-3) as an objective function when calculating the second objective variable data, and may include the above-mentioned (e-20) in the second explanatory variable data. Furthermore, the objective variables calculated by the second optimization unit 49 may include (f-7) to (f-15). Furthermore, (b-28), (b-29), (b-34), (b-35), (b-30), (b-31), (b-36), (b-37), and (b-38) may be obtained by feeding back (f-7) to (f-15), respectively. With this configuration, the production planning system 1 can create overall production plan data 60 and individual production plan data 61 that are more accurate and in line with actual production.

[0088] In the above-described embodiments, each component can be freely substituted or added between the respective embodiments as long as it falls within the technical scope of the present invention. [Explanation of symbols]

[0089] 1. Production planning system 10 First production base 11 Second production base 12 Third production base 13 Fourth Production Base 14 Relay Station 15 Shipping base 45 First input section 46 1st Optimization Section 47 General Planning Department 48 Second input section 49 Second Optimization Section 50 Individual Planning Department 100 products 101 First intermediate product 102a 2nd intermediate product 102b Second intermediate product 103 Third intermediate product

Claims

1. A production planning system that produces multiple types of products through the production of products at multiple production bases and ships them from a shipping base directly from the production bases or via a relay base, a first input unit for inputting first explanatory variable data including the type of product, the number of products, and the timing of production; a first optimization unit that solves an optimization problem using first explanatory variable data input to the first input unit, with the objective function being to minimize costs while satisfying a first constraint condition, and calculates a first objective variable including a production volume of the product at each production base; an overall plan creation unit that creates overall production plan data including a production completion time of each product produced at each production base using the first objective variable calculated by the first optimization unit; a second input unit for inputting second explanatory variable data including a time of change in recipe between products and a production end time of each product when each product is produced at one production base in accordance with the overall production plan data; and a second optimization unit that calculates, from second explanatory variable data input to the second input unit, an optimization problem having as its objective function the minimization of the largest difference between the production end time of the product at the one production base in the overall production plan data and the production end time of each product when produced at the one production base in accordance with the overall production plan data, while satisfying a second constraint condition, and calculates a second objective variable including a production sequence and a production start time of each product at the one production base.

2. the second optimization unit is capable of solving an optimization problem from each second explanatory variable data at each production base to calculate each second objective variable, 2. The production planning system according to claim 1, further comprising an individual plan creation unit that creates individual production plan data including a production sequence and a production start time of products at each production base using each second objective variable calculated by the second optimization unit.

3. the first input unit is capable of inputting, as the first explanatory variable data, a difference between a production end time of each product at each production base in the overall production plan data and a production end time of each product when produced at each production base in accordance with the overall production plan data, when the differences are input to the first input unit, the first optimization unit solves an optimization problem based on the differences and recalculates the first objective variable; 2. The production planning system according to claim 1, wherein the overall plan creation unit updates the overall production plan data using the first objective variable recalculated by the first optimization unit.

4. the overall production plan data is a production plan for a first period, the first period is divided into a plurality of second periods, and a production volume at each production base is planned for each of the plurality of second periods; 4. The production planning system according to claim 3, wherein when a third period has elapsed, the third period is a period shorter than the first period and shorter than the shortest period among the second periods, and the difference is calculated and input as the first explanatory variable data to the first input unit.

5. 5. The production planning system according to claim 1, wherein the costs include at least one of the following costs (1) to (7): (1) Production costs at each production site (2) Costs of changing product recipes at each production site (3) Inventory storage costs for materials and products at each production site (4) Transportation costs between production bases (5) Transportation costs from the most downstream production base to the relay base and / or the shipping base (6) Penalty costs due to production delays (7) External purchase costs of raw materials and / or ingredients

6. 5. The production planning system according to claim 1, wherein the first constraint condition includes at least one of the following (10) to (17): (10) Production costs per batch at each production site (11) Production time per batch at each production site (12) Batch production volume at each production site (13) Safety stock at each production base (14) Upper and / or lower limits of production volume in one cycle at each production site (15) Upper and / or lower limits on production volume at each production base within a specified period (16) Upper and / or lower limits on production time at each production site within a specified period (17) The upper limit of inventory at the relay point and / or the shipping point

7. The plurality of types of products includes a foam molded product, 5. The production planning system according to claim 1, wherein the second constraint condition includes at least one of the following (20) to (27): (20) Production sequence among specific products (21) Production interval between products (22) Product curing and filling times (23) Upper limit of simultaneous foaming series (24) Upper limit of simultaneous filling series (25) Upper limit of same-color filling series (26) The period from the production of the product to the shipment of the product from the shipping base. (27) Limit on the number of recipe changes between products

8. The cost includes a cost value according to the following (28) and a cost value according to the following (29), The first explanatory variable data includes the following (30) to (41): In calculating the second objective variable, an optimization problem is solved in which the objective function is to minimize the following (42), The second explanatory variable data includes the following (43): The second objective variables include the following (30) to (33), (36) to (39), and (40):

3. The production planning system according to claim 2, wherein (30) to (33), (36) to (39), and (40) in the second objective variable are fed back to (30) to (33), (36) to (39), and (40) in the first explanatory variable data. (28) Prescription change reduction costs (29) Similarity with past overall production plan data (30) Preparation costs for each product type at each production site and / or each production line (31) Preparation time for each product type at each production site and / or each production line (32) Recipe change costs for each production site and / or each production line by product type (33) Recipe change time for each product type at each production site and / or each production line (34) Cost reduction of formula changes by priority product type for each production base and / or each manufacturing line (35) Time required to reduce prescription changes by priority product type for each production site and / or each manufacturing line (36) Preparation costs for each production facility and / or each production line by product type and period (37) Preparation time for each production facility and / or each production line by product type and period (38) Recipe change costs by product type and period for each production site and / or each production line (39) Recipe change time by product type and period for each production site and / or each production line (40) The degree of similarity with the combination of varieties of products that have been produced simultaneously by period at each production base and / or each production line, and the degree of recommendation for simultaneous production (41) Production volume by product type and period based on past overall production plan data, and the number of overall production plan data to be acquired (42) Similarity with past individual production plan data (43) Production volume by product type and time based on past individual production plan data, and the number of individual production plan data to be acquired

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