Ordering system

Abstract

We provide an ordering system that can avoid space constraints in areas such as parts storage and production sites. [Solution] An ordering system 1 for ordering the delivery of multiple types of parts by specifying the quantity and delivery time, comprising a controller 4 that creates and transmits order data. The controller 4 determines the required parts, their quantities, and delivery times as order data. From the required parts, it determines the additional quantity of each part that can be loaded together until the cart is full, based on the ratio 6 of parts that can be loaded together on the same cart and the total number of parts that can be loaded together until the cart is full. The controller 4 then adds the parts and quantities, including the additional quantities, to the order data.

Description

Technical Field

[0001] This invention relates to a system for ordering multiple types of components that make up a predetermined product during the production process of the product.

Background Art

[0002] When assembling and manufacturing a predetermined product, it is necessary to supply multiple types of components that make up the product to the production process in the required quantities and at the right time. These components may be procured from the outside instead of being produced simultaneously with the product. For such components, it is necessary to place orders and receive deliveries in a timely and accurate manner. The types and quantities of components required, as well as the timing of use, etc., can be determined based on the production plan of the product.

[0003] For example, in the system described in Patent Document 1, in response to inquiries from suppliers, etc., in order to adjust and manage the scheduled delivery of ordered components and materials, the daily required quantity of each component and material is calculated from the production standard plan data to calculate the daily required number of deliveries, and the calculated results are referenced and displayed. Also, the order-receiving and production system described in Patent Document 2 transmits the delivery date and price based on the response from the terminal of the component manufacturer of the components used in the product ordered from the customer terminal to the customer terminal, and based on the order from the customer terminal, issues an instruction to the terminal of the component manufacturer to deliver the components, and is configured to assemble the product with the components delivered based on the component delivery instruction. That is, the method of Patent Document 2 is a method of performing production without stocking components by delivering the ordered components from the manufacturer and delivering them to the designated date and location, and using the delivery truck as a trolley or warehouse.

[0004] Furthermore, the system described in Patent Document 3 sets the same delivery date for each component based on the received delivery date data, the recognized assembly period, and the recognized name of each component. Then, based on the longest procurement period among the recognized procurement periods, the recognized name of each component, and the set delivery date, the same order date is set for each component. The order information stored in the order information storage unit is output from the output unit as appropriate. Based on the output order information, the components are ordered from the parts manufacturer on the set order date, and the ordered parts are delivered from the parts manufacturer on the set delivery date. In essence, the method described in Patent Document 3 is configured to allow multiple types of parts to be ordered and delivered in the required quantities and at the required time. Furthermore, the parts procurement method described in Patent Document 4 is a method in which, in accordance with the product production plan, a unit production plan quantity is calculated for each short unit period, multiple procurement points are set within that unit period, and the unit production plan quantity is allocated to each procurement point as an allocated production plan quantity, and the procurement quantity of each part is calculated and ordered according to the allocated production plan quantity, and for each lead time from order to delivery at each procurement point, if the lead time required for each delivery is different, the unit production plan quantity is allocated to each procurement point in an amount corresponding to the length of each lead time and allocated as an allocated production plan quantity.Therefore, in the method described in Patent Document 4, when multiple types of parts are ordered and delivered together, the production plan quantity using those parts is set considering the lead time from order to delivery of those parts, so that temporary surpluses or shortages of parts are avoided or suppressed. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2002-334246 [Patent Document 2] Japanese Patent Publication No. 2004-265172 [Patent Document 3] Japanese Patent Publication No. 2005-085229 [Patent Document 4] Patent No. 4333096 [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] The systems or methods described in the aforementioned patent documents allow for the production site to have the correct number of parts for use in a product. However, the system described in Patent Document 1 does not take into account the timing of delivery of ordered parts or how to stock the parts after delivery, which may lead to space constraints at the production site. Furthermore, in the system described in Patent Document 2, the delivery truck holds the ordered parts until they are needed at the production site. In particular, in the case of high-mix, low-volume production, the large number of parts can lead to varying delivery timings, reducing the loading efficiency of the delivery truck or increasing waiting times for delivery, thus worsening delivery efficiency. Moreover, the methods described in Patent Documents 3 and 4 allow for the ordering and delivery of multiple types of parts in a batch according to a plan, thus avoiding or suppressing shortages or surpluses of parts at the production site. However, if, for example, each type of part is loaded onto a trolley for delivery and stocking, the space occupied by the trolleys and parts will be large, which may lead to space constraints at the production site or parts storage area.

[0007] This invention was made in view of the above-mentioned technical problems, and aims to provide an ordering system that can avoid the shortage of space for storing parts in production sites and other locations. [Means for solving the problem]

[0008] This invention provides an ordering system for ordering the delivery of multiple types of parts by specifying the quantity and delivery time, in order to achieve the above objective, comprising a controller that creates and transmits order data, wherein the controller determines the required parts, the quantity of the parts, and the delivery time as the order data, and from the ratio of parts that can be loaded together on the same trolley and the total number of parts that can be loaded together to fill the trolley, it determines the additional quantity of each part that can be loaded together to fill the trolley, and adds the parts and quantities including the additional quantity to the order data.

[0009] In this invention, the controller may be configured to determine the required parts, their quantities, and delivery dates based on at least one of the specifications of the product to be manufactured, the production plan, and the inventory information of the parts.

[0010] In this invention, the controller includes mixed loading master data that defines a trolley capable of loading each of the parts, the ratio of parts that can be mixed and loaded onto the trolley, and the maximum amount of parts that the trolley can load, and the additional quantity may be determined based on the mixed loading master data.

[0011] In this invention, the number of delivery flights within a predetermined period for delivering the ordered parts is predetermined, and the controller assigns the delivery dates included in the order data to the delivery flights, and for parts whose delivery dates are not assigned to the delivery flights, the controller may assign a delivery date to a delivery flight that is immediately preceding the delivery date not assigned to the delivery flight for other parts that can be delivered together.

[0012] In this invention, the controller may include delivery master data that defines the type and number of delivery services for each component, and the allocation of delivery services may be performed based on the delivery master data. [Effects of the Invention]

[0013] According to this invention, since multiple types of parts are mixed and loaded onto the same trolley for delivery, the number of trolleys required can be reduced. As a result, when the delivered parts are stored in a parts storage area or production site along with the trolleys, the space occupied by the parts and trolleys can be reduced. Furthermore, by setting the ratio of the mixed parts to a predetermined ratio, such as a ratio based on the number used in the product, the lead time from delivery to use can be shortened, and consequently, space constraints caused by parts and trolleys occupying space for extended periods can be avoided or mitigated. In addition, if there are limitations on the number of deliveries, the delivery date can be shifted to the delivery date immediately preceding the delivery date of other parts that share the same components, and the deliveries can be consolidated. This allows for the lead time of each component to be shortened as much as possible without unnecessarily increasing the number of deliveries, and consequently, space constraints in parts storage areas and production sites can be avoided or mitigated. [Brief explanation of the drawing]

[0014] [Figure 1] This is a schematic block diagram showing the configuration of one embodiment of this invention. [Figure 2] This is a diagram illustrating the structure of the mixed master data. [Figure 3] This is a diagram illustrating the structure of the delivery service master data. [Figure 4] This is a flowchart illustrating an example of control performed by the controller. [Figure 5] (a) is a front view showing the necessary parts loaded onto the trolley, and (b) is a front view showing the trolley fully loaded with other parts. [Figure 6] (a) is a chart showing the delivery dates of part A and part B, and (b) is a chart showing the dates on which those parts will be delivered. [Figure 7] This is a diagram illustrating an example of allocating the delivery dates of those parts to four different delivery routes.

Best Mode for Carrying Out the Invention

[0015] Next, embodiments of the present invention will be described with reference to the accompanying drawings. Note that the embodiments described below are merely examples of implementing the present invention and do not limit the present invention.

[0016] FIG. 1 shows an example of an embodiment of the present invention in a block diagram. The ordering system 1 is a system for ordering parts from the ordering source 2 to the parts supplier 3. The ordering source 2 is, for example, a factory that assembles and manufactures a predetermined product using a plurality of types of parts. Also, the parts supplier 3 is, for example, a parts factory that manufactures a plurality of types of parts from raw materials, or a parts trading company that collects a variety of parts and sells them according to orders.

[0017] The ordering source 2 is provided with a controller 4 that creates ordering data for the required parts and outputs the ordering data to the parts supplier 3. The controller 4 is mainly composed of a microcomputer having an arithmetic element (CPU), a storage element (RAM, ROM), and various interfaces, and is equipped with a display, a keyboard (not shown respectively), etc. The controller 4 creates ordering data by performing calculations according to a predetermined program using the input data and the data stored in advance, and is configured to output the data to the terminal 5 at the parts supplier 3 via communication means such as the Internet or a LAN.

[0018] Here, the items to be included in the order data include the required parts, their quantities, and the delivery time. It is normal to pre-assign a part number consisting of symbols such as numbers and letters to the parts. Therefore, the required parts are specified by their part numbers. Also, the delivery time may be a date, or it may be a date and time. These required parts, their quantities, and the delivery time are determined based on the product to be manufactured and its manufacturing date and time. If manufacturing a vehicle as a product, the required parts, their quantities, and the delivery time can be determined based on the vehicle specifications, the production plan such as the number of units and the scheduled completion date, and the inventory information which is the status of the parts inventory. Therefore, these vehicle specifications, its production plan, and the inventory information are input to the controller 4.

[0019] The ordering system 1 described here is a system suitable for producing products using a variety of small quantities of parts. Therefore, multiple types of parts are ordered simultaneously, and the frequency of simultaneously delivering multiple types of parts is high. Also, in order to save the labor for reloading and avoid damage to the parts during reloading, the parts are left in the parts storage area or the product production site while mounted on a transport cart (hereinafter simply referred to as a cart). Also, from the viewpoint of the stability and transport efficiency of the cart during transport, it is preferable to fully load the cart with parts. In order to meet such situations and requirements, there may be cases where multiple types of parts are mixed and loaded (co-loaded) on one cart. The co-loading master data 6 which is the basic data for obtaining the quantity of parts when co-loading parts is stored in, for example, a ROM and provided to the controller 4.

[0020] An example of the co-loading master data 6 is shown in FIG. 2. In the example shown here, the part (part number), the different co-loading code for each part, the ratio of the part when co-loading, and the maximum load capacity of the cart on which the part is placed are determined. Note that the different co-loading code is a symbol indicating the cart on which the part is to be placed. The example shown in FIG. 2 shows that part number A and part number B can be co-loaded on the cart with the code "123" at a ratio of "2:3" for a total of 8 pieces.

[0021] Controller 4 stores, for example in ROM, delivery master data 7 used to determine the delivery route so that ordered parts are delivered on the specified delivery date. An example of this is shown in Figure 3, where a "delivery code" and "number of deliveries" are defined for each part (part number). The "delivery code" is a symbol assigned to delivery services such as trucks, and parts with the same "delivery code" can be delivered on the same delivery service. The "number of deliveries" is the number of deliveries within a predetermined period, such as a week or a month, and can be predetermined considering the operational efficiency of the delivery services.

[0022] Controller 4 includes an order data creation unit 4a that creates order data using the input data and stored data described above. As mentioned above, the order data includes the type of part (i.e., part number), its quantity, and the delivery date. Because data regarding the product to be manufactured, such as vehicle specifications, is input, the required parts (part numbers) are identified based on that data. In addition, the required quantity of parts and the date on which those parts are needed are calculated from the input production plan, such as the number of units to be produced and the production period. Then, based on the inventory status of parts, newly required parts, their quantities, and delivery dates are calculated. The order data creation unit 4a creates order data by performing these calculations.

[0023] The controller 4 is equipped with a data transmission unit 4b that transmits the above-mentioned order data to the parts supplier 3. The order data transmitted from the data transmission unit 4b is transmitted to the parts supplier 3's terminal 5 via a communication means such as the internet or LAN. Based on the transmitted order data, the parts supplier 3 collects the parts, loads them onto a designated cart, and delivers them to the ordering party 2 at the designated date and time using a delivery service 8.

[0024] Next, a specific example of an order executed by the controller 4 described above will be explained with reference to the flowchart shown in Figure 4. The routine shown in Figure 4 is executed as needed when it becomes necessary to order new parts required for vehicle production. The controller 4 has vehicle specifications, as well as the production plan and inventory information mentioned above, and calculates the daily required delivery quantity of each part (part number) based on this input data (step S1). As mentioned above, it is possible to perform this calculation in step S1.

[0025] The example described here involves loading multiple types of parts onto a single trolley for delivery and shipping. Therefore, in step S2, the delivery quantity is determined, including the so-called additional quantity needed to load the parts up to the maximum load capacity. In other words, if the required quantity of parts is less than the maximum load capacity of the trolley, there will be empty space on the trolley, reducing delivery efficiency and making the trolley unstable. Therefore, parts are added to fill the empty space on the trolley. The sum of the required quantity and this added quantity is the total number of parts that can be loaded onto the trolley, which is the maximum load capacity of the trolley.

[0026] To explain in more detail, for example, if three units of part A listed in the mixed load master data in Figure 3 are needed, the code for that trolley is "123", and it can carry up to eight units, so there are "5" empty slots. This state is schematically shown in Figure 5(a). In Figure 5, "part A" is denoted with the symbol "A", similarly "part B" is denoted with the symbol "B", and the trolley is denoted with its code, "123". There are various ways to fill trolley 123 with parts A and B, but in this embodiment of the invention, the five empty slots on trolley 123 are allocated to the mixable parts A and B in their respective ratios, and the allocated number of parts A and B are added to trolley 123 and loaded.

[0027] As shown in Figure 2, the ratio of part A to part B is "2:3". Therefore, when the five available slots on trolley 123 are allocated to parts A and B, there will be "2" slots for part A and "3" slots for part B. It is preferable that the ratio of parts A and B corresponds to the proportion of each part A and B used in a product, or the proportion of each part A and B used in any unit to be manufactured or assembled at the manufacturing site. This is because when one part A (or B) loaded on a single trolley is used up, the other part B (or A) will be used up almost simultaneously.

[0028] By determining the delivery quantity by mixing multiple types of parts A and B in step S2, the trolley 123 can be fully loaded, the number of trolleys required can be reduced to one, and situations such as unnecessarily leaving any of parts A or B on the trolley 123 can be avoided or suppressed. In other words, by reducing the number of trolleys 123 and the time they remain in place, the space occupied by parts and trolleys in the parts storage area or production site can be reduced, thus avoiding or suppressing space constraints.

[0029] Next, the delivery service is determined using the delivery service master data 7 shown in Figure 3 (step S3), and the series of processes is completed. The process in step S3 is as follows: The delivery dates for each part A and B are determined in step S1 as described above. An example of this is shown in Figure 6(a) for half a month in February of a given year. In Figure 6, the symbol "○" indicates that a delivery has been made, and "×" indicates that a delivery has not been made. As shown in the delivery service master data 7 in Figure 3, parts A and B are delivered by the delivery service with code "111", so whether or not a delivery has been made by the delivery service with code "111" is as shown in Figure 6(b). Figure 6(b) is similar to the summary of whether or not each part A and B has been delivered for half a month in February, as shown in Figure 6(a).

[0030] If we consider the "number of deliveries" shown in Figure 3 to be the number of deliveries over a half-month period, then the total of 6 days with deliveries shown in Figure 6(b) are allocated to the number of deliveries "4". In the example shown in Figure 6(b), any two of the 6 days are allocated (reassigned) to delivery services that have other delivery dates allocated to them. The result of the allocation is shown in Figure 7. In that case, it is necessary to determine the delivery service in a way that avoids delays in delivery, so it is allocated to the designated delivery service that has the most recent delivery date allocated to it. In the example shown in Figure 6(b), the delivery on February 4th is allocated to the delivery service on February 3rd, and the delivery on February 9th is allocated to the delivery service on February 8th. In the examples shown in Figures 6 and 7, part A ordered with a delivery date of February 4th and part A ordered with a delivery date of February 9th will be delivered one day earlier, on February 3rd and February 8th, respectively. However, since delivery is made on the nearest delivery date prior to the desired delivery date at the time of ordering, the lead time from delivery to use can be shortened as much as possible, which is advantageous in avoiding space constraints in parts storage areas or production sites.

[0031] Although one embodiment of the present invention has been described above, the present invention is not limited to the above-described embodiment and can be modified as needed. For example, there may be two or more types of parts to be mixed, and the delivery date for consolidating into a predetermined single delivery may be three or more days. Also, when multiple types of parts are mixed on a trolley, if there is a fraction of the number of each type of part based on a predetermined ratio, there will be empty space on the trolley. Whether to deliver with this empty space, or to load appropriate parts into the empty space before delivery, may be decided as appropriate based on the production plan at that time and the timing of subsequent deliveries. Furthermore, the order data does not need to be based on all of the specifications of the product to be manufactured, the production plan, and the inventory information of the parts; it may be based on at least one of them. [Explanation of Symbols]

[0032] 1. Ordering System 2. Ordering party 3. Parts suppliers 4 controllers 4a Order Data Creation Department 4b Data transmission section 5 devices 6. Mixed Master Data 7. Delivery service master data 8 Delivery service 123 bogies A,B parts

Claims

1. An ordering system for ordering the delivery of multiple types of parts by specifying the quantity and delivery date, It includes a controller that creates order data and transmits the created order data, The aforementioned controller, The order data includes the required parts, their quantities, and the delivery date. From the ratio of parts that can be mixed and loaded onto the same trolley and the total number of parts that can be mixed and loaded onto the trolley until it is full, the additional quantity of each part that can be mixed and loaded until the trolley is full is determined. The parts and quantities, including the additional quantities mentioned above, are added to the order data. An ordering system characterized by the following:

2. The ordering system according to claim 1, The aforementioned controller, The required parts, their quantities, and delivery dates are determined based on at least one of the following: the specifications of the product to be manufactured, the production plan, and the inventory information of the parts. An ordering system characterized by the following:

3. An ordering system according to claim 1 or 2, The aforementioned controller, The system includes a master data set that defines a trolley capable of loading each of the aforementioned parts, the ratio of parts that can be mixed and loaded onto the trolley, and the maximum amount of the aforementioned parts that can be loaded onto the trolley. The aforementioned additional quantity is determined based on the aforementioned mixed master data. An ordering system characterized by the following:

4. The ordering system according to claim 1, The number of delivery flights within a specified period for delivering the aforementioned ordered parts is predetermined. The aforementioned controller, The delivery date included in the aforementioned order data is assigned to the aforementioned delivery service. For parts whose delivery date is not assigned to the aforementioned delivery service, the delivery service for other parts that can be delivered together will be the delivery service immediately preceding the aforementioned delivery date that has an assigned delivery date. An ordering system characterized by the following:

5. The ordering system according to claim 4, The aforementioned controller, The system includes delivery master data that defines the type of delivery service and the number of deliveries for each of the aforementioned parts, The aforementioned allocation of delivery services is performed based on the aforementioned delivery service master data. An ordering system characterized by the following:

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