Production management system, production management method, and production management program

Abstract

To provide a production management system, a production simulation device, a production simulation method, and a production simulation program that can accurately arrange management articles.SOLUTION: A production management system comprises: a storage unit that stores a product master including the quantity of stock of products and components, and a management article master in which at least one of the products and the components to be produced is registered as management articles; and a control unit that can refer to at least the product master to set the provisional number of management articles to be arranged. The control unit is configured to calculate the predicted quantity of stock of the management articles considering the provisional number to be arranged, and is configured to automatically calculate the predicted quantity of stock again and display the calculated predicted quantity of stock when the product master is updated.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a production management system, a production management method, and a production management program. [Background technology]

[0002] Conventionally, there is known a production management system that includes a bill of materials construction unit that creates a bill of materials for MRP (material requirements planning) calculation, a plan reading unit that reads in as input the production plan for the final product / parts, confirmed requirement information, and confirmed order information, and a generation search unit that uses the bill of materials constructed by the bill of materials construction unit and the plan read in by the plan reading unit to search for generation information corresponding to the plan to be processed (for example, Patent Document 1).

[0003] In the production management system described in Patent Document 1, the bill of materials creation unit is configured to read item information describing information on items to be manufactured and procured, item generation information describing, for each generation, procurement attributes such as safety stock amount, lead time, and bulk quantity at a certain point in time, and information after changes to the procurement method of items such as lot consolidation, individual, or fixed quantity ordering, and configuration information describing the parent-child configuration relationships between items, and create a bill of materials.

[0004] Furthermore, the production management system described in Patent Document 1 performs requirements deployment in accordance with the item generation information found by the generation search unit, and at that time, when a change of generation occurs, it takes over the time-series inventory, and then performs material requirements deployment based on the definitions of the new item information using the time-series inventory amount after the takeover as the base point, and includes an MRP calculation unit that generates the necessary procurement orders. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 3022423 Summary of the Invention [Problem to be solved by the invention]

[0006] The production management system described in Patent Document 1 is configured to search for applicable item generation information based on the requirement date at the time of processing each requirement, perform chronological inventory calculations using the searched item generation information, calculate the order date and order quantity, and generate a procurement order.

[0007] However, the production management system in Patent Document 1 calculates inventory and generates procurement orders using item generation information at the time of processing each requirement, so if the item generation information is updated later or if the item information is suddenly changed to information not included in the generation item information, the time-series inventory and procurement amount cannot be recalculated based on the new item information, and the procurement order cannot be updated either.

[0008] Furthermore, because the procurement quantity is calculated automatically and procurement orders are generated, it is not possible to manually set the procurement quantity or visually check the time-series inventory changes before and after the procurement quantity is reflected. This creates the problem that the user cannot simulate the production plan at their own discretion, and also cannot confirm whether the procurement has been carried out accurately.

[0009] One aspect of the present invention is a production management system, a production management method, and a production management program that can arrange for controlled items with high accuracy. [Means for solving the problem]

[0010] A production management system according to one aspect of the present invention includes a memory unit that stores a product master including inventory quantities of products and parts, and a management item master that registers at least one of the products and parts that are to be produced to stock as management items, and a control unit that can set tentative order quantities for the management items, wherein the control unit is configured to calculate a predicted inventory quantity of the management items taking into account the tentative order quantities, and is configured to automatically recalculate and display the predicted inventory quantity when at least one of the product master and the tentative order quantities is changed.

[0011] In one aspect of the present invention, a production management method includes a production management device that includes a memory unit that stores a product master including inventory quantities of products and parts, and a managed item master that registers at least one of the products and parts that are to be produced to stock as managed items, and a control unit that can set tentative order quantities for the managed items, and that calculates a predicted inventory quantity for the managed items taking into account the tentative order quantities, and automatically recalculates and displays the predicted inventory quantity when at least one of the product master and the tentative order quantity is changed.

[0012] A production management program according to one aspect of the present invention causes a production management device, which includes a memory unit that stores a product master including inventory quantities of products and parts, a managed item master that registers at least one of the products and parts that are to be produced to stock as managed items, and a control unit that can set tentative order quantities for the managed items, to calculate a predicted inventory quantity of the managed items taking into account the tentative order quantities, and automatically recalculate and display the predicted inventory quantity when at least one of the product master and the tentative order quantities is changed.

[0013] According to one aspect of the production management system, production management method, and production management program of the present invention, the predicted inventory quantity is automatically recalculated and displayed when at least one of the product master and the provisional order quantity is changed, thereby enabling accurate ordering of managed items. [Effects of the Invention]

[0014] According to the production management system, production management method, and production management program of one aspect of the present invention, it is possible to arrange for items to be managed with high accuracy. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a schematic diagram showing a production management system according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a functional block diagram showing the production management device according to the first embodiment. [Figure 3] FIG. 3 is a diagram illustrating an example of an order list according to the first embodiment. [Figure 4]FIG. 4 is a diagram showing an example of product information according to the first embodiment. [Figure 5] FIG. 5 is a diagram illustrating an example of a component configuration of a product according to the first embodiment. [Figure 6] FIG. 6 is a diagram showing an example of the management item master according to the first embodiment. [Figure 7] FIG. 7 is a diagram showing the managed item master after the calculation of the provisional order quantity of the leg parts according to the first embodiment. [Figure 8] FIG. 8 is a diagram showing the managed item master after the calculation of the provisional order quantity of pipe B according to the first embodiment. [Figure 9] FIG. 9 is a diagram showing the managed item master after making arrangements for stock production according to the first embodiment. [Figure 10] FIG. 10 is a diagram showing an example of a managed product display screen according to the first embodiment. [Figure 11] FIG. 11 is a flowchart showing an example of processing executed by the production management system according to the first embodiment. [Figure 12] FIG. 12 is a diagram illustrating an example of the management item master according to the second embodiment. [Figure 13] FIG. 13 is a diagram showing the managed item master after the calculation of the provisional order quantity of the leg parts according to the second embodiment. [Figure 14] FIG. 14 is a diagram showing the managed item master after the calculation of the provisional order quantity of pipe B according to the second embodiment. [Figure 15] FIG. 15 is a diagram showing the managed item master after making arrangements for stock production according to the second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0016] The best mode for carrying out the present invention will be described below with reference to the drawings. Note that the following embodiments do not limit the inventions according to the claims, and not all of the combinations of features described in the embodiments are necessarily essential to the solution of the invention.

[0017] [Overall configuration of the production management system according to the first embodiment] FIG. 1 is a schematic diagram showing a production management system according to a first embodiment of the present invention. First, a production management system 1 according to an embodiment of the present invention will be outlined with reference to Fig. 1. The production management system 1 according to the first embodiment generally includes a production management device 10, as shown in Fig. 1.

[0018] 1, the production management device 10 includes an input unit 20, a display unit 30, a control unit 40, and a storage unit 50. The production management device 10 according to the first embodiment is, for example, an electronic computer such as a desktop personal computer, a laptop computer, or a tablet terminal.

[0019] The input unit 20 is composed of input devices such as a keyboard, a mouse, a touchpad, a joystick, etc., and by operating the input unit 20, in addition to the information input function normally required in the production management device 10, it is possible to perform operations such as selecting products and parts to be registered as management items C, which will be described later, inputting the provisional order quantity, which will be described later, and giving instructions to arrange for the production of management items C that have been provisionally ordered, which will be described later.

[0020] FIG. 10 is a diagram showing an example of a managed product display screen according to the first embodiment. The display unit 30 has a display as a display device. In addition to the screen display functions normally required in the production management device 10, the display unit 30 displays a control item display screen 32 and the like. The control item display screen 32 includes information of the control item master 57, as shown in FIG.

[0021] The display unit 30 is also configured to be able to display the predicted inventory quantity on the managed item display screen 32. Furthermore, the display unit 30 is also configured to be able to simultaneously display on the managed item display screen 32 the predicted inventory quantity before calculating the tentative order quantity and the predicted inventory quantity taking the tentative order quantity into consideration.

[0022] Furthermore, the display unit 30 may be configured as a touch panel (touch screen) having the functions of the input unit 20. When the display unit 30 is configured as a touch panel, the user can, for example, operate the display unit 30 to perform various operations on the production management device 10, such as selecting products and parts to be registered as control items C, inputting the number of provisional orders, and issuing instructions to arrange for the production of the control items C that have been provisionally ordered.

[0023] The configurations of the input unit 20 and the display unit 30 are not limited to those described above, and any configuration having equivalent functions (for example, a display means or input means that can be used remotely) can be used instead of the input unit 20 and the display unit 30, and is not limited to this.

[0024] The control unit 40 is configured by, for example, an integrated arithmetic processing device having a CPU (Central Processing Unit) and a GPU (Graphics Processing Unit). As shown in FIG. 1 , the control unit 40 also includes an order management unit 41, a managed product registration unit 43, a tentative order unit 45, and a forecast production management unit 47.

[0025] FIG. 2 is a functional block diagram showing the production management device according to the first embodiment. When an order is received from a business partner, order information 52 is passed to the production management device 10. As shown in FIG. 2, the order management unit 41 is configured to register the order information 52 in an order list 51 (described later) in the storage unit 50. As shown in FIG. 3, the order information 52 includes the product name, quantity, delivery date, etc. The order management unit 41 is also configured to register order information 52 for unofficial orders in the order list 51.

[0026] Furthermore, the order management unit 41 registers product information 54 of the products and parts included in the order information 52 in a product master 53 (described later) in the storage unit 50. Furthermore, when an order is confirmed and manufacturing is required, the order management unit 41 is configured to make arrangements for manufacturing the products and parts included in the order. The order management unit 41 also registers arrangement information 56 of the products and parts for which manufacturing has been arranged in a production arrangement list 55 as production arrangement information 56a.

[0027] In the first embodiment, production arrangements mean issuing instructions to manufacture products and parts. Specifically, this can be done by registering arrangement information in a system used at the manufacturing site, or by printing out work instructions and handing them over to the manufacturing site.

[0028] 2, the control item registration unit 43 is configured to register at least one of products and parts that are the subject of make-to-stock production as control items C in a control item master 57 (described later) in the storage unit 50. Products and parts registered as control items C are those for which increases or decreases in inventory quantity need to be monitored and for which make-to-stock production is required.

[0029] Specifically, these include products with long lead times, small product sizes (component sizes) that do not pose a problem for inventory storage, parts that are common to multiple products and are used frequently, parts that have different manufacturing lots and order lots and require detailed inventory management, etc. By making such products and parts into controlled items C, it is expected that effective forecast production can be carried out.

[0030] In the first embodiment, the user selects products and parts to be registered as control items C, and the control item registration unit 43 accepts the operation to register the control item C, thereby registering the control item C in the control item master 57, but this is not limiting. The tentative ordering unit 45 may determine whether or not to register the products and parts as control items C based on predetermined conditions, and if it determines that they should be registered, may register the products and parts in the control item master 57 as control items C.

[0031] Control item C is configured so that the safety stock quantity and the number of order lots can be set. In the first embodiment, the safety stock quantity is the minimum stock quantity (integer) that is always kept in order to shorten the lead time and prevent stockouts of control item C. In the first embodiment, the number of order lots is the number of production lots, which is a quantity suitable for manufacturing, or the number of purchase lots, which is a quantity suitable for purchasing. The user can set the safety stock quantity and the number of order lots to any number on the control item display screen 32.

[0032] For example, the manufacturing lot size may be the number of products (components) that can be manufactured from a base material (e.g., one sheet of material) with the maximum yield rate, or the maximum number that can be processed simultaneously on a certain machine. Furthermore, the purchasing lot size may be the minimum purchaseable unit or the quantity for which a discount is applied. The safety stock quantity and ordering lot size set for managed item C are used when automatically calculating the tentative ordering quantity, as described below.

[0033] FIG. 6 is a diagram showing an example of the management item master according to the first embodiment. Figure 6 shows the managed item master 57 in the case where a "leg" that is a component of the product "chair" and a "pipe B" that is a component of the "leg" are registered as managed item C in the managed item master 57. For the "leg", the safety stock quantity is set to "10" and the order lot quantity is set to "5", while for the "pipe B", the safety stock quantity is set to "6" and the order lot quantity is set to "1".

[0034] The tentative order unit 45 is configured to be able to set a tentative order quantity for the control item C. In the first embodiment, the tentative order quantity is the quantity of the control item C for which it is desired to arrange for production or place an order in order to maintain an appropriate inventory quantity of the control item C. In the first embodiment, the day on which the tentative order quantity occurs is called the reorder point. Furthermore, the tentative order unit 45 is configured to be able to accept input of the tentative order quantity by the user and set the tentative order quantity.

[0035] Furthermore, the tentative order unit 45 is configured to be able to automatically calculate the tentative order quantity by referring to at least the product master 53. In the first embodiment, as shown in Fig. 2, the tentative order unit 45 is configured to be able to calculate the tentative order quantity by referring to the order list 51 and the product master 53. Furthermore, the tentative order unit 45 automatically calculates the tentative order quantity for each day. Specifically, the tentative order quantity for the management item C is automatically calculated by repeating the following procedure from the product (or part) at the highest level in the parts configuration including the management item C to the parts at lower levels.

[0036] First, the tentative order unit 45 calculates the number of uses of the management item C by referring to the order information 52 in the order list 51 and the product information 54 in the product master 53. The predicted inventory quantity of the management item C is reduced by the number of uses of the management item C. The number of uses of the management item C occurs when the target management item C is shipped in response to an order, or when it is used in the arrangement and tentative arrangement of a higher-level product (or part) that has the target management item C in its parts configuration.

[0037] The number of managed items C used when used due to the arrangement of a product (part) at a higher level is calculated by multiplying the number of products (parts) at the higher level used by the number of managed items C used per product (part). In addition, if the product information 54 of the product master 53 contains switching information (to be described later), the tentative order unit 45 calculates the number of items used based on the part configuration that applies to each date.

[0038] Next, the tentative order unit 45 refers to the product information 54 in the product master 53 and records the order quantity of the management item C. The order quantity is generated when a production order is made, and the management item C is manufactured in the amount for which production order has been made, so the predicted inventory quantity of the management item C increases. Then, the tentative order unit 45 calculates the predicted inventory quantity by subtracting the calculated usage quantity of the management item C from the predicted inventory quantity (or actual inventory quantity) of the previous day and adding the recorded order quantity of the management item C. In the first embodiment, the actual inventory quantity that serves as the base for calculating the predicted inventory quantity is the carryover inventory quantity confirmed by the user on a specified closing date, but is not limited to this.

[0039] Thereafter, the tentative order unit 45 calculates the tentative order quantity based on the calculated predicted inventory quantity and makes a tentative order for the controlled item C. Alternatively, the user can manually set the tentative order quantity based on the calculated predicted inventory quantity. The tentative order unit 45 according to the first embodiment is configured to be able to set reorder point conditions, and automatically calculates the tentative order quantity when the reorder point conditions are met. Examples of the reorder point conditions include when the predicted inventory quantity is negative, when the predicted inventory quantity is lower than the safety inventory quantity, or when the predicted inventory quantity is lower than the next usage quantity of the controlled item C. Alternatively, the tentative order unit 45 may be configured to calculate the tentative order quantity when a predetermined number of days or more have passed since the previous reorder point.

[0040] Specifically, the tentative order unit 45 is configured to calculate, as the tentative order quantity, the minimum number that makes the predicted stock quantity equal to or greater than the safety stock quantity when the calculated predicted stock quantity, i.e., the predicted stock quantity before calculating the tentative order quantity, is lower than the safety stock quantity of the managed item C. More specifically, the tentative order quantity is calculated as the minimum number, among multiples of the order lot quantity of the managed item C, that makes the predicted stock quantity equal to or greater than the safety stock quantity. The tentative order quantity calculated by the tentative order unit 45 is displayed on the managed item display screen 32 of the display unit 30, as shown in FIGS. 2 and 10.

[0041] The tentative order unit 45 is also configured to calculate the predicted inventory quantity of the management item C taking into consideration the tentative order quantity. Specifically, the tentative order unit 45 subtracts the calculated usage quantity of the management item C from the predicted inventory quantity (or actual inventory quantity) of the previous day, and calculates the predicted inventory quantity taking into consideration the calculated tentative order quantity by adding the recorded order quantity of the management item C to the automatically calculated or manually set tentative order quantity of the management item C. After calculating the predicted inventory quantity, the tentative order unit 45 displays the predicted inventory quantity on the management item display screen 32 of the display unit 30, as shown in FIGS. 2 and 10.

[0042] Fig. 7 is a diagram showing the control item master after calculating the provisional order quantity of the leg according to the first embodiment. Fig. 8 is a diagram showing the control item master after calculating the provisional order quantity of the pipe B according to the first embodiment. The specific automatic calculation of the tentative order quantity will be described with reference to Figures 6 to 8. Note that the numbers in parentheses in Figures 7 and 8 are the usage quantity and predicted stock quantity when the tentative order quantity is reflected. Also, all blank spaces for the usage quantity, tentative order quantity, and order quantity in Figures 6 to 8 are "0."

[0043] First, the tentative order unit 45 calculates the tentative order quantity for "legs." As shown in Figure 3, the number of "chairs" to be used (delivery quantity) is "15" on April 7th and "23" on April 10th. As a result, "legs" will be required on the dates taking into account the three-day lead time known from the "chair" product information 54 (see Figure 4), that is, April 5th and April 8th.

[0044] The number of "legs" used on April 5th is calculated by multiplying the number of "chairs" delivered (15) by the number of "legs" used per "chair" (1), which is "15" as shown in Figure 6. Similarly, the number of "legs" used on April 8th is "23".

[0045] As shown in FIG. 3, the order for "chairs" (order number "002") with a delivery date of April 7 has already been arranged for production, and therefore the order quantity for "legs" on April 5 is "15," as shown in FIG. 6. Therefore, the predicted inventory quantity for "legs" on April 5 is "10," which is calculated from the predicted inventory quantity for "legs" on April 4 (the previous day) and the number of "legs" used and the number of orders on April 5. Because the predicted inventory quantity for "legs" on April 5 is not below the safety inventory quantity for "legs," which is "10," tentative order unit 45 does not calculate the tentative order quantity for "legs" on April 5, as shown in FIG. 7.

[0046] As shown in FIG. 3, the order for "chairs" (order number "001") with a delivery date of April 10 has not yet been arranged for production, so the order quantity for "legs" on April 8 is "0", as shown in FIG. 6. Therefore, the predicted inventory quantity for "legs" on April 8 is "-13", which is calculated by the predicted inventory quantity for "legs" on April 7 (the previous day) and the number of "legs" used and the number of orders on April 8. Because the predicted inventory quantity for "legs" on April 8 is lower than the safety inventory quantity for "legs", which is "10", tentative order unit 45 calculates the tentative order quantity for "legs" on April 8.

[0047] Specifically, the tentative order quantity is calculated as the minimum number that will make the predicted inventory quantity for the "leg" on April 8 equal to or greater than the safety inventory quantity for the "leg." Here, the minimum number that will not fall below the safety inventory quantity for the "leg" of 10 is "23." However, the tentative order unit 45 is configured to calculate the minimum number, among multiples of the order lot quantity for controlled item C, that will make the predicted inventory quantity equal to or greater than the safety inventory quantity, as the tentative order quantity. Therefore, as shown in FIG. 7, the tentative order unit 45 calculates the minimum number, among multiples of "5," the order lot quantity for the "leg," that will make the predicted inventory quantity for the "leg" on April 8 equal to or greater than the safety inventory quantity for the "leg," that is, "25," as the tentative order quantity for the "leg" on April 8, and makes a tentative order for the "leg."

[0048] Furthermore, the tentative order unit 45 calculates the predicted stock quantity of "leg parts" for April 8, taking into consideration the calculated tentative order quantity of "leg parts." The predicted stock quantity taking into consideration the tentative order quantity of "leg parts" for April 8 is "12," based on the predicted stock quantity of "leg parts" for April 7 (the previous day), and the number of "leg parts" used, the number ordered, and the tentative order quantity for April 8.

[0049] Next, the tentative order unit 45 calculates the tentative order quantity for "pipe B." Since the parts expansion of "legs," which are at a higher level in the parts configuration than pipe B, has been completed, the result is used. As shown in Figure 7, the number of "legs" used is "15" on April 5th and "23" on April 8th. This means that "Pipe B" will be needed on the dates that take into account the two-day lead time that can be seen from the "legs" product information 54 (see Figure 4), that is, April 4th and April 7th.

[0050] The number of "Pipe B" units used on April 4th is calculated by multiplying the number of "legs" used, "15," by the number of "Pipe B" units used per "leg," "1 / 8," which is "15 / 8" as shown in Figure 7. Similarly, the number of "Pipe B" units used on April 7th is "23 / 8." Here, the number of "Pipe B" units required for the provisional order number of "legs" on April 8th, "25," is "25 / 8." Therefore, when the calculation includes the provisional order number of "legs," the number of "Pipe B" units used on April 7th is "6 (48 / 8)."

[0051] As mentioned above, the order for the "chair" with a delivery date of April 7th has already been ordered, and the "legs" to be used have also been ordered, so the order quantity for "Pipe B" on April 4th is "2," the smallest multiple (integer multiple) of "1," the order lot quantity for "Pipe B," that is greater than or equal to the quantity to be used, as shown in Figure 7.

[0052] Therefore, the predicted inventory quantity for "Pipe B" on April 4th is "49 / 8", which is calculated from the predicted inventory quantity for "Pipe B" on April 3rd (the previous day) and the usage and order quantities for "Pipe B" on April 4th. Because the predicted inventory quantity for "Pipe B" on April 4th is not below the safety inventory quantity for "Pipe B", which is "6 (48 / 8)", the tentative order unit 45 does not calculate the tentative order quantity for "Pipe B" on April 4th, as shown in FIG. 8.

[0053] As mentioned above, the order for the "chair" with a delivery date of April 10th has not yet been ordered for production, and the "legs" to be used have not yet been ordered for production either, so the order quantity for "Pipe B" on April 7th is "0", as shown in Figure 7. Therefore, if there is no tentative order for "legs" on April 8th, the predicted inventory quantity for "Pipe B" on April 7th will be "13 / 4 (26 / 8)", as shown in Figure 6, based on the predicted inventory quantity for "Pipe B" on April 6th (the previous day), the usage quantity of "Pipe B" on April 7th (23 / 8), and the order quantity.

[0054] However, because a tentative order for the "leg part" is placed on April 8, the predicted inventory quantity for "Pipe B" on April 7 must be calculated taking into account the tentative order for the "leg part" on April 8. Therefore, as shown in FIG. 7, the predicted inventory quantity for "Pipe B" on April 7 is "1 / 8", which is calculated from the predicted inventory quantity for "Pipe B" on April 6 (the previous day), the usage quantity of "Pipe B" on April 7 (6), and the order quantity. Because the predicted inventory quantity for "Pipe B" on April 7 is lower than the safety inventory quantity for "Pipe B," which is "6 (48 / 8)," the tentative order unit 45 calculates the tentative order quantity for "Pipe B" on April 7.

[0055] Specifically, similar to the calculation of the tentative order quantity for "legs," the tentative order unit 45 calculates, as the tentative order quantity for "Pipe B" on April 7, the smallest number among multiples (integer multiples) of "1," which is the order lot number for "Pipe B," that will make the forecasted inventory quantity for "Pipe B" on April 7 equal to or greater than the safety inventory quantity for "Pipe B," as shown in Fig. 8. Here, the smallest number that will not fall below the safety inventory quantity for "Pipe B," "6 (48 / 8)," is "47 / 8," so the tentative order unit 45 calculates "6 (48 / 8)," which is the smallest multiple of the order lot number for "Pipe B" that is equal to or greater than "47 / 8," as the tentative order quantity for "Pipe B," as shown in Fig. 8, and makes a tentative order for "Pipe B."

[0056] The tentative order unit 45 also calculates the predicted stock quantity for "Pipe B" on April 7th, taking into account the calculated tentative order quantity for "Pipe B." The predicted stock quantity taking into account the tentative order quantity for "Pipe B" on April 7th is "49 / 8," which is calculated from the predicted stock quantity for "Pipe B" on April 6th (the previous day) and the usage quantity, order quantity, and tentative order quantity for "Pipe B" on April 7th. Furthermore, the tentative order unit 45 displays the calculated predicted stock quantity and tentative order quantity on the managed item display screen 32 of the display unit 30.

[0057] As described above, the production management system 1 according to the first embodiment is configured to be able to manage the usage and predicted inventory of the managed item C as fractions with the number of parts obtainable from the base material as the denominator. In this specification, the "number of parts obtainable from the base material" also includes the usage amount of material obtainable from one base material (e.g., paint, packaging material, adhesive, etc.). For example, if one can of "Paint B600" shown in FIG. 5 is sufficient to paint 30 "legs," the denominator would be "30." Furthermore, the usage amount of "Paint B600" per "leg" is managed as "1 / 30."

[0058] Furthermore, when the tentative order unit 45 receives an input of a tentative order quantity from the user, it not only sets the tentative order quantity for the received management item C, but also calculates the tentative order quantities for other management items C that are affected by the tentative order quantity of the received management item C. For example, when the user inputs the tentative order quantity for "legs," since "pipe B" is also required accordingly, the tentative order unit 45 calculates the tentative order quantity for "pipe B."

[0059] Furthermore, the tentative order unit 45 is configured to automatically recalculate and display the predicted stock quantity of the management item C when at least one of the product master 53 and the tentative order quantity is changed. Specifically, the tentative order unit 45 is configured to automatically recalculate the predicted stock quantity of the management item C when the product master 53 is updated by overwriting the product information 54 related to the products and parts registered as the management item C in the management item master 57 based on switching information.

[0060] Furthermore, the tentative order unit 45 is configured to automatically recalculate the tentative order quantity of the managed item C by referring to the order list 51 and the updated product master 53 when the recalculated predicted stock quantity satisfies the condition of the order point, and to further calculate the predicted stock quantity of the managed item C taking into account the calculated tentative order quantity.

[0061] Similarly, the tentative order unit 45 is configured to automatically recalculate the predicted stock quantity of the management item C when the order list 51 is updated. Specifically, the tentative order unit 45 is configured to automatically recalculate the predicted stock quantity of the management item C when the order list 51 is updated due to a change in the order information 52 related to the products and parts registered in the management item master 57 as the management item C.

[0062] Furthermore, the tentative order unit 45 is configured to automatically recalculate the tentative order quantity of the managed item C by referring to the updated order list 51 and product master 53 when the recalculated predicted stock quantity satisfies the condition of the order point, and to further calculate the predicted stock quantity of the managed item C taking into account the calculated tentative order quantity.

[0063] 2, the forecast production management unit 47 is configured to be able to arrange for the production of the provisionally ordered control item C. In the first embodiment, the forecast production management unit 47 is configured to receive an instruction from the user to arrange for the production of the provisionally ordered control item C, and to make arrangements for the production of the received control item C. Specifically, as described above, the provisional order unit 45 automatically and immediately calculates the provisional order quantity of the control item C, and displays it on the control item display screen 32 of the display unit 30.

[0064] The user can check the tentative order quantity for control item C on the control item display screen 32 and, if necessary, modify the tentative order quantity and the tentative order schedule for control item C. If there are no problems, the user instructs the forecast production management unit 47 to make production arrangements for the tentatively ordered control item C. When the forecast production management unit 47 makes production arrangements for the tentatively ordered control item C, the tentative order is confirmed as a production arrangement that has been arranged. Then, the tentative order quantity in the control item master 57 is moved to the order quantity. In addition, the forecast production management unit 47 registers the arrangement information 56 for the control item C for which production arrangements have been made in the production arrangement list 55 as forecast arrangement information 56b.

[0065] FIG. 9 is a diagram showing the managed item master after making arrangements for stock production according to the first embodiment. Specifically, when the forecast production management unit 47 places an order for the production of the "legs" and "pipe B" that were provisionally ordered as shown in Fig. 8, the provisional order quantity is confirmed as the order quantity as shown in Fig. 9. The number entered in the provisional order quantity in Fig. 8 is moved to the order quantity in Fig. 9, and it can be seen that the number shown in parentheses in Fig. 8 has been confirmed.

[0066] In addition, the prospective production management unit 47 may be configured to determine whether or not production arrangements should be made for the controlled item C based on specified conditions, and if it is determined that production arrangements should be made, to automatically make production arrangements for the controlled item C.

[0067] The storage unit 50 has storage media such as a hard disk drive (HDD) and a solid state drive (SSD), and stores various data in a readable and writable manner. As shown in Fig. 1, the storage unit 50 stores an order list 51, a product master 53, a production arrangement list 55, a managed item master 57, and a production management program 58. Furthermore, the storage unit 50 stores programs necessary for controlling each part of the production management device 10.

[0068] The order list 51 is configured to be able to register multiple pieces of order information 52. The order information 52 can be changed, for example, when there is a change in the delivery date or the quantity of the unofficial order. The product master 53 includes multiple pieces of product information 54. The product information 54 includes information such as the product drawing number, product name, manufacturing process, and lead time.

[0069] Furthermore, product information 54 includes the inventory quantities of products and parts, the parts configuration of the product, and changeover information. The parts configuration indicates the hierarchical structure of the parts that make up the product and the number of parts used. Each part included in the parts configuration also has its own product information 54.

[0070] As shown in Figure 5, the component configuration indicates the components used by product name, and the number in parentheses indicates the number of components used per product (component). In the first embodiment, the number of components used can be entered and managed as a fraction. The number of components used, "1 / 8," indicates that eight components can be obtained from one piece of "Pipe B" that is the base material for the "leg." The number of components used, which is indicated as an integer, has a denominator of "1."

[0071] The switching information includes the changed parts configuration when the parts configuration is changed due to a change in parts used, a design change, a change in materials used, etc., and the date and time when the change will be applied.

[0072] The production arrangement list 55 stores arrangement information 56. Specifically, the production arrangement list 55 stores arrangement information 56 of products and parts for which production arrangements have been made by the order management unit 41 as production arrangement information 56a, and stores arrangement information 56 of managed items C for which production arrangements have been made by the forecast production management unit 47 as forecast arrangement information 56b. The production arrangement information 56a includes the order quantities of products and parts. The forecast arrangement information 56b includes the tentative order quantity of managed items C. In the managed item master 57, at least one of the products and parts for which forecast production is to be made is registered as managed items C. In addition, the managed item master 57 is configured to be able to register the safety stock quantity and order lot quantity of managed items C.

[0073] The production management program 58 causes the production management device 10 to calculate the predicted inventory quantity of the managed item C taking into account the provisional order quantity, and automatically recalculates and displays the predicted inventory quantity when at least one of the product master 53 and the provisional order quantity is changed.

[0074] [Production management method according to the first embodiment] FIG. 11 is a flowchart showing an example of processing executed by the production management system according to the first embodiment. Next, the production management method of the production management system 1 according to the first embodiment will be described with reference to Fig. 11. In the production management method of the production management system 1 according to the first embodiment, the production management device 10 calculates the predicted inventory quantity of the managed item C taking into account the tentative order quantity, and automatically recalculates and displays the predicted inventory quantity when at least one of the product master 53 and the tentative order quantity is changed.

[0075] In the first embodiment, the explanation is based on the assumption that the order information 52 is registered in the order list 51 in the memory unit 50 of the production management device 10 and that the management item C has already been registered in the management item master 57, but this is not limiting.

[0076] First, the tentative order unit 45 of the control unit 40 of the production management device 10 references the order information 52 in the order list 51 and the product information 54 in the product master 53 (S10 in FIG. 11: information reference step). Next, the tentative order unit 45 calculates the usage quantity of the management item C based on the referenced order information 52 and product information 54 (S11 in FIG. 11: usage quantity calculation step). Furthermore, the tentative order unit 45 counts the order quantity of the management item C based on the referenced product information 54 (S12 in FIG. 11: order quantity counting step).

[0077] The tentative order unit 45 of the control unit 40 then calculates the predicted inventory quantity by subtracting the calculated usage quantity of the control item C from the predicted inventory quantity (or actual inventory quantity) of the previous day and adding the recorded order quantity of the control item C (S13 in FIG. 11: predicted inventory quantity calculation step).Then, the tentative order unit 45 determines whether the calculated predicted inventory quantity of the control item C, i.e., the predicted inventory quantity of the control item C before calculating the tentative order quantity, is lower than the safety inventory quantity of the control item C (S14 in FIG. 11: inventory quantity determination step).

[0078] If the calculated predicted inventory quantity is not less than the safety inventory quantity (NO in S14 of FIG. 11), the tentative order unit 45 of the control unit 40 does not calculate the tentative order quantity, and the production management device 10 ends the series of processes. On the other hand, if the calculated predicted inventory quantity is less than the safety inventory quantity (YES in S14 of FIG. 11), the tentative order unit 45 calculates the tentative order quantity (S15 of FIG. 11: tentative order quantity calculation step). In addition, the tentative order unit 45 makes a tentative order for the controlled item C at the calculated tentative order quantity.

[0079] Specifically, the tentative order unit 45 of the control unit 40 calculates the tentative order quantity as the smallest multiple of the order lot quantity of the managed item C for which the predicted stock quantity has been calculated, which will make the predicted stock quantity equal to or greater than the safety stock quantity. Then, the tentative order unit 45 of the control unit 40 recalculates the predicted stock quantity of the managed item C taking into account the calculated tentative order quantity (S16 in FIG. 11: predicted stock quantity recalculation step).

[0080] The tentative order unit 45 of the control unit 40 also displays the calculated tentative order quantity and predicted inventory quantity of the control item C on the control item display screen 32 of the display unit 30 (S17 in FIG. 11: calculation result display step). The user may check the tentative order information (tentative order quantity, tentative order schedule, etc.) of the control item C on the control item display screen 32 and manually correct the tentative order quantity (S1 in FIG. 11: tentative order quantity change step).

[0081] Thereafter, the tentative order unit 45 of the control unit 40 determines whether the tentative order quantity has been manually changed (S18 in FIG. 11: tentative order quantity change determination step). If it is determined that the tentative order quantity has been changed (YES in S18 in FIG. 11), the tentative order unit 45 of the control unit 40 automatically recalculates and displays the predicted stock quantity and other related tentative order quantities based on the changed tentative order quantity (post-change calculation step). Furthermore, the tentative order unit 45 makes a new tentative order for the controlled item C using the new tentative order quantity. If it is determined that the tentative order quantity has not been changed (NO in S18 in FIG. 11), the predicted stock quantity and other related tentative order quantities are not recalculated.

[0082] Furthermore, the tentative order unit 45 of the control unit 40 determines whether or not at least one of the order list 51, the product master 53, and the tentative order quantity has been updated after the tentative order (S19 in FIG. 11: information update determination step). The information update determination step may be executed periodically after a predetermined time has elapsed, or may be executed when a predetermined operation is performed, such as when the management item display screen 32 is closed due to an interruption of work and then reopened, or when the management item display screen 32 is reloaded.

[0083] If it is determined that at least one of the order list 51, the product master 53, and the tentative order quantity has been updated (YES in S19 of FIG. 11), the tentative order unit 45 of the control unit 40 refers to the updated information, automatically recalculates and displays the predicted inventory quantity and tentative order quantity (post-update calculation step). In addition, the tentative order unit 45 makes a new tentative order for the controlled item C using the newly calculated tentative order quantity.

[0084] If it is determined that neither the order list 51 nor the product master 53 has been updated (NO in S19 of FIG. 11), the forecast inventory quantity and the tentative order quantity are not recalculated. If there are no problems after checking, the user instructs the forecast production management unit 47 of the control unit 40 of the production management device 10 to make production arrangements for the tentatively ordered managed item C (S2 of FIG. 11: production arrangement instruction process).

[0085] The forecast production management unit 47 of the control unit 40 receives an instruction from the user to arrange for production of the control item C that has been provisionally ordered, and makes the production arrangement for the received control item C (S20 in FIG. 11: production arrangement process). The provisional order for the control item C for which production arrangement has been made is confirmed as a production arrangement that has been arranged, and the provisional order quantity is changed to the order quantity. In addition, the forecast production management unit 47 registers the order information 56 for the control item C for which production arrangement has been made as forecast order information 56b in the production arrangement list 55 (S21 in FIG. 11: order information registration process). Through the above steps, a series of production management methods by the production management system 1 according to the first embodiment is executed.

[0086] [Advantages of the production management system, production management method, and production management program according to the first embodiment] As described above, the production management system 1 according to the first embodiment includes a memory unit 50 that stores a product master 53 including inventory quantities of products and parts, a management item master 57 that registers at least one of the products and parts that are the subject of forecast production as management items C, and a control unit 40 that can set a tentative order quantity for management items C by referring to at least the product master 53. The control unit 40 is configured to calculate the predicted inventory quantity for management items C taking the tentative order quantity into consideration, and is configured to automatically recalculate and display the predicted inventory quantity when at least one of the product master 53 and the tentative order quantity is changed.

[0087] The production management system 1 according to the first embodiment is configured in this way so that it automatically recalculates the predicted inventory quantity when at least one of the product master 53 and the tentative order quantity is changed. This means that the predicted inventory quantity can be calculated in real time, reflecting the latest changes to the product master 53 and tentative order quantity at the time of calculation, which has the advantage of enabling the controlled item C to be ordered with high accuracy.

[0088] In addition, because the recalculated predicted inventory quantity is displayed, the user can check in real time whether the arrangement is accurate. Furthermore, because the tentative order quantity can be set and the predicted inventory quantity can be calculated taking the tentative order quantity into consideration, the user can simulate the production plan before making production arrangements.

[0089] Furthermore, in the production management system 1 according to the first embodiment, the control unit 40 is configured to be able to automatically calculate the tentative order quantity by at least referring to the product master 53. This configuration has the advantage that the tentative order quantity can be calculated without the user having to manually set the tentative order quantity, and the predicted inventory quantity is also calculated taking the calculated tentative order quantity into consideration, allowing for accurate ordering of the controlled item C.

[0090] Furthermore, in the production management system 1 according to the first embodiment, the control item master 57 is configured to be able to register the safety stock quantity of the control item C, and the control unit 40 is configured to calculate, as the tentative order quantity, the minimum number that makes the predicted stock quantity equal to or greater than the safety stock quantity when the predicted stock quantity before calculating the tentative order quantity is lower than the safety stock quantity of the control item C. This configuration has the advantage of always being able to maintain the safety stock quantity of the control item C while being able to order the minimum necessary quantity, thereby enabling the control item C to be ordered with high accuracy.

[0091] Furthermore, in the production management system 1 according to the first embodiment, the control unit 40 is configured to calculate the minimum number of multiples of the order lot number of the control item C that will make the predicted inventory quantity equal to or greater than the safety inventory quantity as the tentative order quantity. This configuration has the advantage of enabling the minimum necessary quantity to be ordered taking into account the order lot number, thereby enabling the control item C to be ordered with high accuracy.

[0092] Furthermore, the production management system 1 according to the first embodiment is configured to be able to manage the number of uses and the predicted inventory of controlled items C as fractions with the number of parts obtainable from the base material as the denominator. This configuration has the advantage that it is possible to bridge the gap between the units used in manufacturing and the units used in purchasing even when they are different, and it is possible to standardize the calculation method for determining the provisional order quantity, thereby enabling the controlled items C to be ordered with high accuracy.

[0093] Furthermore, the production management system 1 according to the first embodiment includes a display unit 30 capable of displaying the predicted stock quantity, and the display unit 30 is configured to simultaneously display the predicted stock quantity before calculating the tentative order quantity and the predicted stock quantity taking the tentative order quantity into consideration. This configuration allows the user to visually check the change in the predicted stock quantity before and after calculating (reflecting) the tentative order quantity, thereby providing the advantage of allowing the user to confirm whether accurate ordering has been performed and to accurately order the controlled item C.

[0094] [Configuration of the control unit of the control device of the production management system according to the second embodiment] The configuration of the control unit 40 of the production management device 10 in the production management system 1 according to the second embodiment will be described. Note that descriptions of configurations that overlap with those of the first embodiment will be omitted as appropriate. As with the control unit 40 of the first embodiment, the control unit 40 of the production management device 10 includes an order management unit 41, a managed item registration unit 43, a tentative order unit 45, and a prospective production management unit 47, as shown in FIG.

[0095] The order management unit 41 is configured to, when an order is confirmed and manufacturing is required, arrange for the production of products and parts other than the control item C included in the order and the components of the control item C. Specifically, as shown in Figure 5, there is a product "chair" whose components are "legs" that are registered in the control item master 57 as the control item C and a "seat" that is not registered as the control item C.

[0096] The "legs" are made up of "pipe B", which is registered in control item master 57 as control item C, and "leg frame", "screws", "casters", and "paint B600", which are not registered as control item C. The seat is made up of "seat frame" and "pipe A", which are not registered as control item C. The "seat frame" and "leg frame" are further made up of multiple parts.

[0097] In this case, if an order including the product "chair" is confirmed and the product "chair" and its component parts need to be manufactured, the order management department 41 will arrange for the manufacture of the product "chair" and also arrange for the manufacture of the "seat" and its component parts, which are not registered as managed item C.

[0098] The temporary order unit 45 is configured to be able to set the tentative order quantity of the management item C. The temporary order unit 45 is also configured to calculate the predicted inventory quantity of the management item C taking into account the tentative order quantity. Furthermore, in the second embodiment, the temporary order unit 45 is configured to calculate the tentative order quantity and predicted inventory quantity of the component parts of the management item C taking into account the tentative order quantity and predicted inventory quantity of the management item C.

[0099] 2, the provisional order unit 45 is configured to be able to provisionally order the control item C and the components of the control item C. In the second embodiment, the provisional order unit 45 is configured to calculate the provisional order quantity based on the calculated predicted inventory quantity and to provisionally order the control item C and the components of the control item C.

[0100] Fig. 12 is a diagram showing an example of a management item master according to the second embodiment. Fig. 13 is a diagram showing a management item master after calculating the provisional order quantity for the leg according to the second embodiment. Fig. 14 is a diagram showing a management item master after calculating the provisional order quantity for the pipe B according to the second embodiment. The specific automatic calculation of the tentative order quantity will be described with reference to Figures 12 to 14. Note that the numbers in parentheses in Figures 13 and 14 are the usage quantity and predicted stock quantity when the tentative order quantity is reflected. Also, all blank spaces for the usage quantity, tentative order quantity, and order quantity in Figures 12 to 14 are "0."

[0101] First, the tentative order unit 45 calculates the tentative order quantity for "legs." As shown in Figure 3, the number of "chairs" to be used (delivery quantity) is "15" on April 7th and "23" on April 10th. As a result, "legs" will be required on the dates taking into account the three-day lead time known from the "chair" product information 54 (see Figure 4), that is, April 5th and April 8th.

[0102] The number of "legs" used on April 5th is calculated by multiplying the delivery quantity of "chairs," which is "15," by the number of "legs" used per "chair," which is "1," and is "15," as shown in Figure 12. Similarly, the number of "legs" used on April 8th is "23." As shown in Figure 3, an order for "chairs" (order number "002") with a delivery date of April 7th has already been arranged for production. However, because "legs" are registered as managed item C, production arrangements have not been made by the order management department 41.

[0103] Therefore, the order quantity for "leg parts" on April 5th is "0", as shown in FIG. 12. Therefore, the predicted inventory quantity for "leg parts" on April 5th is "-5", which is the result of the predicted inventory quantity for "leg parts" on April 4th (the previous day) and the usage quantity and order quantity of "leg parts" on April 5th. Since the predicted inventory quantity for "leg parts" on April 5th is less than the safety stock quantity for "leg parts", "10", the tentative order unit 45 calculates the tentative order quantity for "leg parts" on April 5th. As shown in FIG. 13, the tentative order unit 45 calculates the smallest number of multiples of "5", which is the order lot quantity for "leg parts", that makes the predicted inventory quantity for "leg parts" on April 5th equal to or greater than the safety stock quantity for "leg parts", i.e., "15", as the tentative order quantity for "leg parts" on April 5th, and makes a tentative order for "leg parts".

[0104] The tentative order unit 45 also calculates the predicted stock quantity of "leg parts" for April 5, taking into account the calculated tentative order quantity of "leg parts." The predicted stock quantity taking into account the tentative order quantity of "leg parts" for April 5 is "10," based on the predicted stock quantity of "leg parts" for April 4 (the previous day), the number of "leg parts" used, the number ordered, and the tentative order quantity for April 5.

[0105] As shown in Figure 3, the order for "chairs" (order number "001") with a delivery date of April 10 has not yet been ordered for production, so the order quantity for "legs" on April 8 is "0", as shown in Figure 12. Therefore, the predicted inventory quantity for "legs" on April 8 is "-28", as shown in Figure 12, based on the predicted inventory quantity for "legs" on April 7 (the previous day), "-5", and the usage and order quantity of "legs" on April 8.

[0106] Here, since a tentative order is placed for the "leg" on April 5, the predicted inventory quantity for the "leg" on April 8 must be calculated taking into account the tentative order for the "leg" on April 5. As shown in Figure 13, the predicted inventory quantity for the "leg" on April 7 is "10" when the tentative order for the "leg" on April 5 is taken into account, and the predicted inventory quantity for the "leg" on April 8 is "-13" when the tentative order for the "leg" on April 5 is taken into account.

[0107] Even when the tentative order for the "leg part" on April 5 is taken into consideration, the predicted inventory quantity for the "leg part" on April 8 is less than the safety stock quantity of "10" for the "leg part", so the tentative order unit 45 calculates the tentative order quantity for the "leg part" on April 8. As shown in Fig. 13, the tentative order unit 45 calculates the smallest number of multiples of "5", which is the order lot quantity for the "leg part", that will make the predicted inventory quantity for the "leg part" on April 8 equal to or greater than the safety stock quantity for the "leg part", that is, "25", as the tentative order quantity for the "leg part" on April 8, and makes a tentative order for the "leg part".

[0108] Furthermore, the tentative order unit 45 calculates the predicted stock quantity of "leg parts" for April 8, taking into consideration the calculated tentative order quantity of "leg parts." The predicted stock quantity taking into consideration the tentative order quantity of "leg parts" for April 8 is "12," based on the predicted stock quantity of "leg parts" for April 7 (the previous day), and the number of "leg parts" used, the number ordered, and the tentative order quantity for April 8.

[0109] Next, the tentative order unit 45 calculates the tentative order quantity for "pipe B." Since the parts expansion of "legs," which are at a higher level in the parts configuration than pipe B, has been completed, the result is used. As shown in Figure 12, the number of "legs" used is "15" on April 5th and "23" on April 8th. This means that "Pipe B" will be needed on the dates that take into account the two-day lead time that can be seen from the "legs" product information 54 (see Figure 4), that is, April 4th and April 7th.

[0110] The number of "Pipe B" used on April 4th is calculated by multiplying the number of "legs" used, "15", by the number of "Pipe B" used per "leg", "1 / 8", which is "15 / 8", as shown in Figure 12. Similarly, the number of "Pipe B" used on April 7th is "23 / 8". As mentioned above, production arrangements have already been made for the order for the "chair" due on April 7th. However, since the "legs" and the "Pipe B" used for the "legs" are registered as managed item C, production arrangements have not been made by the order management department 41. Therefore, the number of "Pipe B" ordered on April 4th is "0", as shown in Figure 13.

[0111] Therefore, if there is no tentative order for "legs" on April 5, the predicted inventory quantity for "Pipe B" on April 4 will be "33 / 8" as shown in Figure 12, based on the predicted inventory quantity for "Pipe B" on April 3 (the previous day), the usage quantity of "Pipe B" on April 5 of "15 / 8", and the order quantity, respectively. However, because a tentative order for "legs" is made on April 5, the predicted inventory quantity for "Pipe B" on April 4 must be calculated taking into account the tentative order for "legs" on April 5. Therefore, the predicted inventory quantity for "Pipe B" on April 4 will be "9 / 4 (18 / 8)", based on the predicted inventory quantity for "Pipe B" on April 3 (the previous day), the usage quantity of "Pipe B" on April 5 of "15 / 4 (30 / 8)", and the order quantity, as shown in Figure 13. Since the predicted inventory quantity for "Pipe B" on April 4th is lower than the safety inventory quantity for "Pipe B" of "6 (48 / 8)", the provisional order unit 45 calculates the provisional order quantity for "Pipe B" on April 4th.

[0112] Specifically, similar to the calculation of the tentative order quantity for "legs," the tentative order unit 45 calculates, as the tentative order quantity for "Pipe B" on April 4, the smallest number among multiples (integer multiples) of "1," which is the order lot number for "Pipe B," that will make the forecasted inventory quantity for "Pipe B" on April 4 equal to or greater than the safety inventory quantity for "Pipe B," as shown in Fig. 14. Here, the smallest number that will not fall below the safety inventory quantity for "Pipe B," "6 (48 / 8)," is "15 / 4 (30 / 8)." Therefore, the tentative order unit 45 calculates "4 (32 / 8)," which is the smallest multiple of the order lot number for "Pipe B" that is equal to or greater than "15 / 4," as the tentative order quantity for "Pipe B," as shown in Fig. 14, and makes a tentative order for "Pipe B."

[0113] Furthermore, the tentative order unit 45 calculates the predicted stock quantity of "Pipe B" on April 4th, taking into consideration the calculated tentative order quantity of "Pipe B." The predicted stock quantity taking into consideration the tentative order quantity of "Pipe B" on April 4th is "25 / 4 (50 / 8)," which is calculated from the predicted stock quantity of "Pipe B" on April 3 (the previous day), and the usage quantity, order quantity, and tentative order quantity of "Pipe B" on April 4th.

[0114] As mentioned above, the order for the "chair" with a delivery date of April 10 has not yet been ordered for production, and the "legs" to be used have not yet been ordered for production either, so the order quantity for "Pipe B" on April 7 is "0", as shown in Figure 13. Therefore, if there is no tentative order for the "legs" on April 8, the predicted inventory quantity for "Pipe B" on April 7 will be "5 / 4 (10 / 8)", as shown in Figure 12, based on the predicted inventory quantity for "Pipe B" on April 6 (the previous day), "33 / 8", the usage quantity of "Pipe B" on April 7, "23 / 8", and the order quantity.

[0115] However, because a tentative order for the "leg part" is made on April 5, a tentative order for the "leg part" is made on April 8, and a tentative order for "Pipe B" is made on April 4, the estimated inventory quantity for "Pipe B" on April 7 must be calculated taking these tentative orders into consideration. Therefore, as shown in FIG. 13, the estimated inventory quantity for "Pipe B" on April 7 is "1 / 4 (2 / 8)", which is calculated from the estimated inventory quantity for "Pipe B" on April 6 (the previous day), "25 / 4 (50 / 8)", the usage quantity of "Pipe B" on April 7, "6", and the order quantity. Because the estimated inventory quantity for "Pipe B" on April 7 is lower than the safety inventory quantity for "Pipe B", "6 (48 / 8)", the tentative order unit 45 calculates the tentative order quantity for "Pipe B" on April 7.

[0116] Specifically, similar to the calculation of the tentative order quantity for "Pipe B" on April 4, the tentative order unit 45 calculates the smallest number, among multiples (integer multiples) of "1," which is the order lot number for "Pipe B," that will make the forecasted inventory quantity for "Pipe B" on April 7 equal to or greater than the safety inventory quantity for "Pipe B," as the tentative order quantity for "Pipe B" on April 7. Here, the smallest number that will not fall below the safety inventory quantity for "Pipe B," "6 (48 / 8)," is "2¾ (46 / 8)." Therefore, as shown in FIG. 14 , the tentative order unit 45 calculates "6 (48 / 8)," which is the smallest multiple of the order lot number for "Pipe B" that is equal to or greater than "42¾," as the tentative order quantity for "Pipe B," and places a tentative order for "Pipe B."

[0117] The tentative order unit 45 also calculates the predicted stock quantity for "Pipe B" on April 7th, taking into account the calculated tentative order quantity for "Pipe B." The predicted stock quantity taking into account the tentative order quantity for "Pipe B" on April 7th is "25 / 4 (50 / 8)," which is calculated from the predicted stock quantity for "Pipe B" on April 6th (the previous day) and the usage quantity, order quantity, and tentative order quantity for "Pipe B" on April 7th. Furthermore, the tentative order unit 45 displays the calculated predicted stock quantity and tentative order quantity on the managed item display screen 32 of the display unit 30.

[0118] The provisional ordering unit 45 calculates the provisional ordering quantity and predicted inventory quantity of the "leg frame" and "screws," which are components of the "leg" registered as managed item C, and makes provisional orders for these parts.

[0119] As shown in Fig. 2, the forecast production management unit 47 is configured to make arrangements for the production of the provisionally ordered control item C and the components of the control item C. Specifically, in the example shown in Fig. 5, the forecast production management unit 47 makes arrangements for the production of the "leg" and "pipe B" registered in the control item master 57 as the control item C, and the components of the "leg" other than "pipe B."

[0120] In the second embodiment, the prospective production management unit 47 is configured to receive instructions from a user to arrange for the production of control item C and components of control item C that have been provisionally ordered, and to make arrangements for the production of the received control item C and components of control item C. Specifically, as described above, the provisional order quantity of control item C is automatically and immediately calculated by the provisional order unit 45, and is displayed on the control item display screen 32 of the display unit 30.

[0121] The user can check the tentative order quantities of the control item C and its component parts on the control item display screen 32, and, if necessary, modify the tentative order quantities and the tentative order schedules of the control item C and its component parts. If there are no problems, the user instructs the forecast production management unit 47 to make production arrangements for the tentatively ordered control item C and its component parts. When the forecast production management unit 47 makes production arrangements for the tentatively ordered control item C and its component parts, the tentative orders are confirmed as arranged production arrangements. Then, the tentative order quantities in the control item master 57 are changed to the order quantities. In addition, the forecast production management unit 47 registers order information 56 of the component parts of the control item C and control item C for which production arrangements have been made as forecast order information 56b in the production arrangement list 55.

[0122] FIG. 15 is a diagram showing the managed item master after making arrangements for stock production according to the second embodiment. Specifically, when the forecast production management unit 47 orders the production of the "legs" and "pipe B" that were provisionally ordered as shown in Fig. 14, the provisional order quantity is confirmed as the order quantity as shown in Fig. 15. The number entered in the provisional order quantity in Fig. 14 is moved to the order quantity in Fig. 15, and it can be seen that the number expressed in parentheses in Fig. 14 has been confirmed.

[0123] 1, the storage unit 50 stores an order list 51, a product master 53, a production arrangement list 55, a managed item master 57, and a production management program 58. The production arrangement list 55 stores arrangement information 56. Specifically, the production arrangement list 55 stores arrangement information 56 of products and parts other than managed item C and component parts of managed item C, for which production arrangement has been made by the order management unit 41, as production arrangement information 56a.

[0124] The production arrangement list 55 also stores, as prospective arrangement information 56b, arrangement information 56 of the controlled item C and the components of the controlled item C, whose production has been arranged by the prospective production management department 47. The production arrangement information 56a includes the quantities of products and parts arranged for production by the order management department 41. The prospective arrangement information 56b includes the tentative order quantities of the controlled item C and the components of the controlled item C.

[0125] [Production management method according to the second embodiment] Next, a production management method of the production management system 1 according to the second embodiment will be described with reference to Fig. 11. Note that descriptions of steps that overlap with those in the first embodiment will be omitted as appropriate.

[0126] The tentative order unit 45 of the control unit 40 displays the calculated tentative order quantity and predicted inventory quantity of the control item C on the control item display screen 32 of the display unit 30 (S17 in FIG. 11: calculation result display step). Similarly to the control item C, the tentative order unit 45 also executes the information reference step through the calculation result display step for the component parts of the control item C (S10 to S17 in FIG. 11). The user may check the information on the tentative orders for the control item C and the component parts of the control item C on the control item display screen 32 and manually correct the tentative order quantity (S1 in FIG. 11: tentative order quantity change step).

[0127] Thereafter, the temporary order unit 45 of the control unit 40 determines whether the temporary order quantity has been manually changed (S18 in FIG. 11: temporary order quantity change determination step). If it is determined that the temporary order quantity has been changed (YES in S18 in FIG. 11), the temporary order unit 45 of the control unit 40 automatically recalculates and displays the predicted stock quantity and other related temporary order quantities based on the changed temporary order quantity (post-update calculation step).

[0128] Furthermore, the temporary ordering unit 45 of the control unit 40 automatically recalculates and displays the temporary order quantities of the components of the management item C whose temporary order quantities have been changed (post-change calculation step). When the temporary order quantity of a component of the management item C is changed, the temporary ordering unit 45 automatically recalculates and displays the temporary order quantities of the components at a lower level than that component. Furthermore, the temporary ordering unit 45 redoes the temporary orders for the management item C and its components using the new temporary order quantities.

[0129] Furthermore, the tentative order unit 45 of the control unit 40 determines whether at least one of the order list 51, the product master 53, and the tentative order quantity has been updated since the tentative order was made (S19 in FIG. 11: information update determination step). If it is determined that at least one of the order list 51, the product master 53, and the tentative order quantity has been updated (YES in S19 in FIG. 11), the tentative order unit 45 of the control unit 40 refers to the updated information and automatically recalculates and displays the predicted inventory quantity and the tentative order quantity (post-update calculation step). Furthermore, the tentative order unit 45 makes a new tentative order for the managed item C and its component parts using the newly calculated tentative order quantity.

[0130] If there are no problems after checking, the user instructs the prospective production management unit 47 of the control unit 40 of the production management device 10 to make production arrangements for the provisionally ordered control item C and the components of the control item C (S2 in FIG. 11: production arrangement instruction process). The prospective production management unit 47 receives an instruction from the user to make production arrangements for the provisionally ordered control item C and the components of the control item C, and makes production arrangements for the received control item C and the components of the control item C (S20 in FIG. 11: production arrangement process).

[0131] The provisional orders for the control item C and the components of the control item C for which production arrangements have been made are confirmed as arranged production arrangements, and the provisional order quantity is changed to the order quantity. Furthermore, the prospective production management unit 47 of the control unit 40 registers order information 56 for the control item C and the components of the control item C for which production arrangements have been made as prospective order information 56b in the production arrangement list 55 (S21 in FIG. 11: order information registration step). Through the above steps, a series of production management methods by the production management system 1 according to the second embodiment are executed.

[0132] [Advantages of the production management system, production management method, and production management program according to the second embodiment] As described above, the production management system 1 according to the second embodiment, like the production management system 1 according to the first embodiment, comprises a memory unit 50 that stores a product master 53 including inventory quantities of products and parts, and a management item master 57 that registers at least one of the products and parts that are the subject of forecast production as management items C, and a control unit 40 that can set a tentative order quantity for management items C by referring to at least the product master 53. The control unit 40 is configured to calculate a predicted inventory quantity for management items C taking the tentative order quantity into consideration, and is configured to automatically recalculate and display the predicted inventory quantity when at least one of the product master 53 and the tentative order quantity is changed.

[0133] The production management system 1 according to the second embodiment is thus configured to automatically recalculate the predicted inventory quantity when at least one of the product master 53 and the tentative order quantity is changed. This allows the predicted inventory quantity to be calculated in real time, reflecting the latest changes to the product master 53 and tentative order quantity at the time of calculation, thereby offering the advantage of being able to accurately order the controlled item C.

[0134] In addition, because the recalculated predicted inventory quantity is displayed, the user can check in real time whether the arrangement is accurate. Furthermore, because the tentative order quantity can be set and the predicted inventory quantity can be calculated taking the tentative order quantity into consideration, the user can simulate the production plan before making production arrangements.

[0135] Furthermore, in the production management system 1 according to the second embodiment, the control unit 40 is configured to be able to automatically calculate the tentative order quantity by at least referring to the product master 53, as in the production management system 1 according to the first embodiment. This means that the tentative order quantity can be calculated without the user having to manually set it, and the predicted inventory quantity is also calculated taking the calculated tentative order quantity into consideration, which has the advantage of allowing the controlled item C to be ordered with high accuracy.

[0136] Furthermore, in the production management system 1 according to the second embodiment, the control item master 57 is configured to be able to register the safety stock quantity of the control item C, as in the production management system 1 according to the first embodiment, and the control unit 40 is configured to calculate, as the tentative order quantity, the smallest number that makes the predicted stock quantity equal to or greater than the safety stock quantity when the predicted stock quantity before calculating the tentative order quantity is lower than the safety stock quantity of the control item C. This configuration has the advantage of always being able to maintain the safety stock quantity of the control item C while being able to order the minimum necessary quantity, thereby enabling the control item C to be ordered with high accuracy.

[0137] Furthermore, in the production management system 1 of the second embodiment, the control unit 40 is configured, like the production management system 1 of the first embodiment, to calculate the minimum number of multiples of the order lot number of the controlled item C that will make the predicted inventory number equal to or greater than the safety inventory number as the provisional order number. This has the advantage that the minimum required quantity can be ordered taking into account the order lot number, allowing the controlled item C to be ordered with high accuracy.

[0138] Furthermore, like the production management system 1 of the first embodiment, the production management system 1 of the second embodiment is configured to be able to manage the number of uses and predicted inventory of controlled items C as fractions with the number of parts obtainable from the base material as the denominator. This makes it possible to bridge the gap between units even when the units used in manufacturing and those used in purchasing are different, and it is possible to standardize the calculation method for determining the provisional order quantity, thereby offering the advantage of being able to accurately order controlled items C.

[0139] Furthermore, like the production management system 1 of the first embodiment, the production management system 1 of the second embodiment is equipped with a display unit 30 capable of displaying the predicted inventory quantity, and the display unit 30 is configured to be able to simultaneously display the predicted inventory quantity before the tentative order quantity is calculated and the predicted inventory quantity taking the tentative order quantity into consideration. This makes it possible to visually check the change in the predicted inventory quantity before and after calculating (reflecting) the tentative order quantity, allowing the user to confirm whether accurate ordering has been made, which has the advantage of allowing the controlled item C to be ordered with precision.

[0140] Furthermore, in the production management system 1 according to the second embodiment, the control unit 40 includes an order management unit 41, a tentative order unit 45 capable of setting the number of provisional orders, and a forecast production management unit 47, the order management unit 41 is configured to make production arrangements for products and parts other than the controlled item C and its constituent parts, the provisional order unit 45 is configured to be able to make provisional orders for the controlled item C and its constituent parts, and the forecast production management unit 47 is configured to make production arrangements for the provisionally ordered controlled item C and its constituent parts.

[0141] By having such a configuration, unlike the production management system 1 of the first embodiment, the order management department 41 makes arrangements for the production of products and parts other than the controlled item C and the components of the controlled item C, and the forecast production management department 47 makes arrangements for the production of the controlled item C and the components of the controlled item C that have been provisionally ordered, so there is no risk of the production arrangements for the controlled item C and the components of the controlled item C overlapping between the order management department 41 and the forecast production management department 47, and there is an advantage that the controlled item C can be arranged more accurately.

[0142] [Variations] Although the preferred embodiments of the present invention have been described above, the technical scope of the present invention is not limited to the scope described in the above-described embodiments. Various modifications and improvements can be made to the above-described embodiments.

[0143] For example, in the first and second embodiments described above, the control unit 40 has been described as being configured to be able to automatically calculate the provisional order quantity by at least referring to the product master 53, but this is not limited to this, and the control unit 40 does not have to be able to automatically calculate the provisional order quantity.

[0144] In the first and second embodiments described above, the management item master 57 is configured to be able to register the safety stock quantity of management item C, and the control unit 40 is configured to calculate, as the tentative order quantity, the smallest number that makes the predicted stock quantity equal to or greater than the safety stock quantity when the predicted stock quantity before calculating the tentative order quantity is lower than the safety stock quantity of management item C. However, this is not limited to this. The management item master 57 does not have to be able to register the safety stock quantity. Furthermore, the control unit 40 can calculate the tentative order quantity using various arbitrary conditions as the order point conditions, as described above.

[0145] In the first and second embodiments described above, the control unit 40 is configured to calculate the tentative order quantity as the smallest multiple of the order lot quantity of the controlled item C that makes the predicted inventory quantity equal to or greater than the safety inventory quantity, but this is not limiting. The control unit 40 may calculate the tentative order quantity without considering the order lot quantity of the controlled item C.

[0146] In the first and second embodiments described above, the production management system 1 has been described as being configured to be able to manage the usage number and predicted inventory number of the controlled item C as a fraction with the number of parts obtainable from the base material as the denominator, but this is not limited to this. The production management system 1 may also manage the usage number and predicted inventory number of the controlled item C all as integers.

[0147] In the first and second embodiments described above, the production management system 1 is described as including the display unit 30 capable of displaying the predicted inventory quantity, and the display unit 30 is configured to be able to simultaneously display the predicted inventory quantity before the tentative order quantity is calculated and the predicted inventory quantity taking the tentative order quantity into consideration, but this is not limiting. The display unit 30 does not have to be able to simultaneously display the predicted inventory quantity before the order quantity is calculated and the predicted inventory quantity taking the tentative order quantity into consideration.

[0148] In the second embodiment described above, the control unit 40 includes an order management unit 41, a tentative order unit 45 capable of setting the number of provisional orders, and a forecast production management unit 47, and the order management unit 41 is configured to make production arrangements for products and parts other than the control item C and its components, the tentative order unit 45 is configured to be able to make provisional orders for the control item C and its components, and the forecast production management unit 47 is configured to make production arrangements for the provisionally ordered control item C and its components, but this is not limiting. For example, the order management unit 41 may make production arrangements for the control item C and its components, and the tentative order unit 45 may not be able to make provisional orders for the control item C's components.

[0149] In the first and second embodiments described above, the control unit 40 of the production management device 10 has been described as including the order management unit 41, the management item registration unit 43, the tentative order unit 45, and the prospect production management unit 47, but is not limited to this. The production management system 1 may include a device including a control unit other than the production management device 10, and some or all of the order management unit 41, the management item registration unit 43, the tentative order unit 45, and the prospect production management unit 47 may be included in the control units of multiple different devices.

[0150] In the second embodiment described above, the tentative order unit 45 is configured to calculate the tentative order quantity and predicted inventory quantity of the component parts of the management item C in consideration of the tentative order quantity and predicted inventory quantity of the management item C. However, the present invention is not limited to this. The tentative order unit 45 does not have to calculate the tentative order quantity and predicted inventory quantity of the component parts of the management item C in consideration of the tentative order quantity and predicted inventory quantity of the management item C. [Explanation of symbols]

[0151] 1 Production management system 10 Production control device 20 Input section 30 Display section 32 Managed items display screen 40 Control Unit 41 Order Management Department 43 Controlled Product Registration Department 45 Provisional Arrest Department 47 Production Management Department 50 Storage section 51 Order List 52 Order Information 53 Product Master 54 Product Information 55 Production Arrangement List 56 Arrangements Information 56a Production arrangement information 56b Prospective Arrangement Information 57 Controlled Product Master 58 Production Management Program C Controlled items

Claims

1. a storage unit for storing a product master including inventory numbers of products and parts, and a control item master for registering at least one of the products and parts to be produced to stock as control items; a control unit capable of setting the provisional order number of the managed items; Equipped with The control unit is configured to calculate a predicted inventory quantity of the managed item taking into consideration the tentative order quantity, and is configured to automatically recalculate and display the predicted inventory quantity when at least one of the product master and the tentative order quantity is changed. Production management system.

2. The control unit is configured to be able to automatically calculate the provisional order quantity by referring to at least the product master. The production management system according to claim 1 .

3. the management item master is configured to be able to register the safety stock quantity of the management item, The control unit is configured to calculate, when the predicted inventory quantity before calculating the tentative order quantity is lower than the safety inventory quantity of the managed item, the minimum number at which the predicted inventory quantity is equal to or greater than the safety inventory quantity as the tentative order quantity. The production management system according to claim 2 .

4. The control unit is configured to calculate, as the tentative order quantity, the smallest multiple of the order lot quantity of the controlled item that makes the predicted inventory quantity equal to or greater than the safety inventory quantity. The production management system according to claim 3 .

5. The number of used items and the predicted inventory number of the managed items are configured to be manageable as fractions with the number of parts obtained from the base material as the denominator. The production management system according to any one of claims 1 to 4.

6. a display unit capable of displaying the predicted inventory quantity, The display unit is configured to simultaneously display the predicted stock quantity before calculating the tentative order quantity and the predicted stock quantity taking the tentative order quantity into consideration. The production management system according to any one of claims 1 to 4.

7. the control unit includes an order management unit, a tentative order unit capable of setting the tentative order quantity, and a make-to-stock production management unit; the order management unit is configured to make arrangements for the production of the products and parts other than the managed items and component parts of the managed items, the temporary ordering unit is configured to be able to temporarily order the managed item and the component parts of the managed item, The forecast production management unit is configured to make arrangements for the production of the provisionally ordered controlled items and the component parts of the controlled items. The production management system according to any one of claims 1 to 4.

8. A production management device includes a storage unit that stores a product master including inventory quantities of products and parts, a managed item master that registers at least one of the products and parts targeted for forecast production as managed items, and a control unit that can set tentative order quantities for the managed items, calculates a predicted inventory quantity for the managed items taking into account the tentative order quantities, and automatically recalculates the predicted inventory quantity when at least one of the product master and the tentative order quantities is changed. Production management methods.

9. A production management device including a storage unit that stores a product master including inventory quantities of products and parts, a managed item master that registers at least one of the products and parts targeted for forecast production as managed items, and a control unit that can set tentative order quantities of the managed items, calculates a predicted inventory quantity of the managed items taking the tentative order quantities into consideration, and automatically recalculates the predicted inventory quantity when at least one of the product master and the tentative order quantities is changed. Production management program.

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