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

Abstract

The present invention is provided with: a storage unit that stores a product master that includes the stock quantity of a product and a component, and a management article master that registers, as a management article, at least one of the product and the component to be expected to be produced; and a control unit that can set the temporary arrangement number of the management article by referring to at least the product master. The control unit is configured to calculate the predicted stock quantity of the management article in consideration of the temporary arrangement number, and is configured to automatically calculate and display the predicted stock quantity again when the product master has been updated.

Description

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

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

[0002] Conventionally, there has been known a production management system that includes a bill of materials creation unit that creates a bill of materials for MRP (Material Requirements Planning) calculations, a plan reading unit that reads in as input a production plan for a final product / parts, confirmed requirement information, and confirmed order information, and a generation search unit that uses the bill of materials created by the bill of materials creation unit and the plan read in by the plan reading unit to search for generation information corresponding to a plan to be processed (for example, see 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 bulk, individual, or fixed quantity ordering, and configuration information describing the parent-child configuration relationships between items, and create a bill of materials.

[0004] The production management system described in Patent Document 1 also 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 in accordance with 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.

[0005] Patent No. 3022423

[0006] The production management system described in Patent Document 1 is configured to search for applicable item generation information based on the required 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 performs inventory calculations and generates procurement orders using item generation information at the time each requirement is processed. Therefore, 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.

[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 the production management system, production management method, and production management program of one embodiment 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.

[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.

[0015] FIG. 1 is a schematic diagram showing a production management system according to a first embodiment of the present invention. FIG. 2 is a functional block diagram showing a production management device according to the first embodiment. FIG. 3 is a diagram showing an example of an order list according to the first embodiment. FIG. 4 is a diagram showing an example of product information according to the first embodiment. FIG. 5 is a diagram showing an example of a parts configuration of a product according to the first embodiment. FIG. 6 is a diagram showing an example of a management item master according to the first embodiment. FIG. 7 is a diagram showing a management item master after calculating the tentative order quantity for a leg part according to the first embodiment. FIG. 8 is a diagram showing a management item master after calculating the tentative order quantity for a pipe B according to the first embodiment. FIG. 9 is a diagram showing a management item master after making a production arrangement for stock production according to the first embodiment. FIG. 10 is a diagram showing an example of a management item display screen 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. 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 tentative order quantity for a leg part according to the second embodiment. FIG. 14 is a diagram showing a management item master after calculating the tentative order quantity for a pipe B according to the second embodiment. FIG. 15 is a diagram showing a management item master after making a production arrangement for stock production according to the second embodiment.

[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 Production Management System According to 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. As shown in Fig. 1, the production management system 1 according to the first embodiment generally includes a production management device 10.

[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 described later, inputting the number of provisional orders described later, and giving instructions to arrange for the production of management items C that have been provisionally ordered described later.

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

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

[0022] 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 management items C, inputting the number of provisional orders, and issuing instructions to arrange for the production of the management items C that have been provisionally ordered.

[0023] The configuration of the input unit 20 and the display unit 30 is not limited to the above-described configuration, and may be replaced with any configuration having equivalent functions (for example, a display means or input means that can be used remotely, etc.).

[0024] The control unit 40 is configured by, for example, an integrated 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 item registration unit 43, a tentative order unit 45, and a forecast production management unit 47.

[0025] 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 the order information 52 of 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 production arrangements for 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 arrangements have been made 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, and specifically, there are methods such as registering arrangement information 56 in a system used at the manufacturing site, or printing out work instructions and handing them over to the manufacturing site.

[0028] 2, the management 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 management items C in a management item master 57 (described later) in the storage unit 50. Products and parts registered as management items C are those for which increases or decreases in inventory quantity need to be monitored and which need to be made-to-stock.

[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 are manufactured in different lots and require detailed inventory management, etc. By treating such products and parts as controlled items C, it is expected that effective forecast production can be carried out.

[0030] In the first embodiment, the production management device 10 registers the control item C in the control item master 57 when the user selects the products and parts to be registered as the control item C and the control item registration unit 43 accepts the operation to register the control item C. However, this is not limiting. In the production management device 10, the tentative order unit 45 may determine whether or not the products and parts should be registered as the control item 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 the control item C.

[0031] The 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 secured in order to shorten the lead time and prevent stockouts of the 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 number of manufacturing lots 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 by a certain machine. Furthermore, the number of purchasing lots may be the minimum purchaseable unit or the quantity for which a discount is applied. The safety stock quantity and order lot quantity set for the management item C are used when automatically calculating the provisional order quantity, as described below.

[0033] Fig. 6 is a diagram showing an example of the management item master according to the first embodiment. Fig. 6 shows the management 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 management item C in the management item master 57. For the "leg", the safety stock quantity is set to "10" and the order lot quantity is set to "5", and 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 set the tentative order quantity by accepting input of the tentative order quantity by the user.

[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 by 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 control 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 control item C is reduced by the number of uses of the control item C. The number of uses of the control item C occurs when the target control 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 control 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). If the product information 54 in 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 calculates 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. The tentative order unit 45 then calculates the predicted inventory quantity by subtracting the calculated number of use of the management item C from the predicted inventory quantity (or actual inventory quantity) of the previous day and adding the calculated order quantity of the management item C. In the first embodiment, the actual inventory quantity that serves as the basis for calculating the predicted inventory quantity is the carryover inventory quantity confirmed by the user on a specified closing date. However, it is not limited to this.

[0039] The tentative order unit 45 then 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 smallest 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 smallest 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 account 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 account 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 managed item master after calculating the tentative order quantity for the leg according to the first embodiment. Fig. 8 is a diagram showing the managed item master after calculating the tentative order quantity for the pipe B according to the first embodiment. Specific automatic calculation of the tentative order quantity will be described with reference to Figs. 6 to 8. Note that the numbers in parentheses in Figs. 7 and 8 are the usage quantity and predicted inventory quantity when the tentative order quantity is reflected. Also, all blank spaces for the usage quantity, tentative order quantity, and order quantity in Figs. 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 delivered quantity of "chairs" ("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 7th has already been ordered for production. Therefore, the order quantity for "legs" on April 5th is "15," as shown in FIG. 6. Therefore, the predicted inventory quantity for "legs" on April 5th is "10," which is calculated from the predicted inventory quantity for "legs" on April 4th (the previous day) and the number of "legs" used and the order quantity on April 5th. The predicted inventory quantity for "legs" on April 5th is not below the safety inventory quantity for "legs," which is "10." Therefore, the tentative order unit 45 does not calculate the tentative order quantity for "legs" on April 5th, as shown in FIG. 7.

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

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

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

[0049] Next, the tentative ordering unit 45 calculates the tentative order quantity for "Pipe B." Since the parts expansion for "Leg," which is at a higher level in the parts configuration than Pipe B, has been completed, the tentative ordering unit 45 uses the result. As shown in FIG. 7, the usage count for "Leg" is "15" on April 5th and "23" on April 8th. As a result, "Pipe B" is required on the dates taking into account the two-day lead time known from the product information 54 for "Leg" (see FIG. 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 FIG. 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 provisional order number of "legs" is included in the calculation, 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. Therefore, the order quantity for "Pipe B" on April 4th is "2", which is the smallest multiple (integer multiple) of "1", the order lot quantity for "Pipe B", that is equal to or greater than 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. 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)". Therefore, 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. Therefore, 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 "legs" is placed on April 8, the estimated inventory quantity for "Pipe B" on April 7 must be calculated taking into account the tentative order for the "legs" on April 8. Therefore, as shown in FIG. 7 , the estimated inventory quantity for "Pipe B" on April 7 is "1 / 8", which is calculated by taking the estimated 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. The estimated inventory quantity for "Pipe B" on April 7 is lower than the safety inventory quantity for "Pipe B" (6 (48 / 8)). Therefore, 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 the "leg," 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." Therefore, as shown in FIG. 8, 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," 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 manage the usage and predicted inventory of the management item C as a fraction 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 amount of material obtained from one base material (e.g., paint, packaging material, adhesive, etc.). For example, if one can of "Paint B600" shown in FIG. 5 can 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 a tentative order quantity input by 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 data 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 data 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 data 57 based on switching information.

[0060] Furthermore, when the recalculated predicted inventory quantity satisfies the order point condition, 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, and further calculate the predicted inventory 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, when the order list 51 is updated due to a change in the order information 52 related to the products and parts registered as the management item C in the management item master 57, the tentative order unit 45 is configured to automatically recalculate the predicted stock quantity of the management item C.

[0062] Furthermore, when the recalculated predicted inventory quantity satisfies the order point condition, 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, and further calculate the predicted inventory 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 make production arrangements for provisionally ordered control items C. In the first embodiment, the forecast production management unit 47 is configured to accept instructions from the user to make production arrangements for provisionally ordered control items C, and to make production arrangements for the accepted control items C. Specifically, as described above, the provisional order unit 45 automatically and immediately calculates the provisional order quantity of control items 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] Figure 9 is a diagram showing the managed item master after making production arrangements for stock production according to the first embodiment. Specifically, when the forecast production management unit 47 makes production arrangements for the "legs" and "pipe B" that were provisionally ordered as shown in Figure 8, the provisional order quantity is confirmed as the order quantity as shown in Figure 9. The number in the provisional order quantity in Figure 8 is moved to the order quantity in Figure 9, and it can be seen that the number in parentheses in Figure 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 a storage medium such as a hard disk drive (HDD) or 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. The storage unit 50 also 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 unofficial order quantity. The product master 53 includes multiple pieces of product information 54. As shown in FIG. 4, the product information 54 includes information such as the product drawing number, product name, manufacturing process, and lead time.

[0069] The product information 54 also includes the inventory quantities of products and parts, the product's parts configuration, 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 serves as the base material for the "leg." The number of components used, 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] 1 and 2, 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 performed 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 the 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 First Embodiment] Figure 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 Figure 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 limited to this.

[0076] First, the tentative order placement 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 placement unit 45 calculates the number of items to be used for management C based on the referenced order information 52 and product information 54 (S11 in FIG. 11: usage quantity calculation step). Furthermore, the tentative order placement unit 45 counts the number of items to be ordered for management C based on the referenced product information 54 (S12 in FIG. 11: order quantity counting step).

[0077] The tentative ordering 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).The tentative ordering unit 45 then 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 a tentative order quantity. Then, 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 a 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 managed item C on the managed item display screen 32 of the display unit 30 (S17 in FIG. 11: calculation result display step). The user may check the information on the tentative order for the managed item C (tentative order quantity, tentative order schedule, etc.) on the managed 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 inventory quantity and other related tentative order quantities based on the changed tentative order quantity (post-change calculation step). Furthermore, the tentative order unit 45 re-issues a 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 tentative order unit 45 does not recalculate the predicted inventory quantity and other related tentative order quantities.

[0082] 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 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 and automatically recalculates and displays the predicted inventory quantity and the tentative order quantity (post-update calculation step).The tentative order unit 45 also 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. After checking the tentative order information, if there are no problems, 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 step).

[0085] The forecast production management unit 47 of the control unit 40 receives an instruction from the user to make a production arrangement for the control item C for which a tentative order has been placed, and makes the production arrangement for the received control item C (S20 in FIG. 11: production arrangement step). The tentative order for the control item C for which a production arrangement has been placed is confirmed as a production arrangement that has already been placed. The tentative order quantity is then changed to the order quantity. The forecast production management unit 47 also registers the order information 56 for the control item C for which a production arrangement has been placed as forecast 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 using the production management system 1 according to the first embodiment are carried out.

[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 comprises a memory unit 50 that stores a product master 53 including the 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 at least to the product master 53, and 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.

[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 product master 53 and changes to the tentative order quantity at the time of calculation, and therefore has the advantage of being able to accurately order the managed item C.

[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, thereby enabling accurate ordering of the controlled item C.

[0090] Furthermore, in the production management system 1 according to the first embodiment, the management item master 57 is configured to be able to register the safety stock quantity of the management 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 management item C. This configuration has the advantage of always being able to maintain the safety stock quantity of the management item C while arranging the minimum necessary quantity, thereby enabling the management 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 procured 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 inventory quantity, and the display unit 30 is configured to simultaneously display the predicted inventory quantity before the calculation of the tentative order quantity and the predicted inventory quantity taking the tentative order quantity into consideration. This configuration allows the user to visually check the change in the predicted inventory quantity before and after the calculation of (reflecting) the tentative order quantity, thereby providing the advantage of enabling the user to check whether the order has been made accurately and to order the controlled item C with high precision.

[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 of the production management system 1 according to the second embodiment will be described. Note that descriptions of the configuration that overlaps with the first embodiment will be omitted as appropriate. The control unit 40 of the production management device 10, like the control unit 40 of the first embodiment, includes an order management unit 41, a managed item registration unit 43, a tentative order unit 45, and a prospect 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 the control item master 57 as control item C, and "leg frame", "screw", "caster", 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 production of the product "chair" and also arrange for the production of the "seat" and its component parts, which are not registered as managed item C.

[0098] The tentative order unit 45 is configured to be able to set the tentative order quantity of the management item C. The tentative 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 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 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 tentative order quantity for legs according to the second embodiment. FIG. 14 is a diagram showing a management item master after calculating the tentative order quantity for pipe B according to the second embodiment. Specific automatic calculation of tentative order quantities will be described with reference to FIGS. 12 to 14. Note that the numbers in parentheses in FIGS. 13 and 14 are the usage quantity and predicted inventory quantity when the tentative order quantity is reflected. Also, all blank spaces for usage quantity, tentative order quantity, and order quantity in FIGS. 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 FIG. 12. Similarly, the number of "legs" used on April 8th is "23." As shown in FIG. 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 unit 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 and order quantity for "leg parts" on April 5th. The predicted inventory quantity for "leg parts" on April 5th is less than the safety stock quantity for "leg parts", "10". Therefore, 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 multiple of "5", the order lot quantity for "leg parts", that will make 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 order quantity, 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 10th has not yet been ordered for production. Therefore, the order quantity for "legs" on April 8th is "0", as shown in Figure 12. Therefore, the predicted inventory quantity for "legs" on April 8th is "-28", as shown in Figure 12, calculated from the predicted inventory quantity for "legs" on April 7th (the previous day), "-5", and the usage and order quantity of "legs" on April 8th.

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

[0107] Even when taking into account the tentative order for the "leg part" on April 5, the predicted inventory quantity for the "leg part" on April 8 is below the safety inventory quantity for the "leg part," which is "10." Therefore, 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 multiple of "5," which is the order lot number 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 inventory quantity for the "leg part," i.e., "25," as the tentative order quantity for the "leg part" on April 8, and makes a tentative order for the "leg part."

[0108] The tentative order unit 45 also calculates the predicted stock quantity of "leg parts" for April 8, 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 8 is "12," based on the predicted stock quantity of "leg parts" for April 7 (the previous day), the number of "leg parts" used, the order quantity, 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 for "Leg," which is at a higher level in the parts configuration than Pipe B, has been completed, the result is used. As shown in FIG. 12, the usage count for "Leg" is "15" on April 5th and "23" on April 8th. As a result, "Pipe B" is required on the dates taking into account the two-day lead time known from the "Leg" product information 54 (see FIG. 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 FIG. 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 unit 41. Therefore, the number of "Pipe B" ordered on April 4th is "0", as shown in FIG. 13.

[0111] Therefore, if there is no tentative order for "legs" on April 5, the predicted inventory quantity for "Pipe B" on April 4 is "33 / 8" as shown in FIG. 12, which is calculated from the predicted inventory quantity for "Pipe B" on April 3 (the previous day), the usage quantity of "Pipe B" on April 5 (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, as shown in FIG. 13, the predicted inventory quantity for "Pipe B" on April 4 is "9 / 4 (18 / 8)" as shown in FIG. 13, which is calculated from the predicted inventory quantity for "Pipe B" on April 3 (the previous day), the usage quantity of "Pipe B" on April 5 (15 / 4 (30 / 8)), and the order quantity, respectively. The predicted inventory quantity for "Pipe B" on April 4 is lower than the safety inventory quantity for "Pipe B" of "6 (48 / 8)." Therefore, the tentative order unit 45 calculates the tentative order quantity for "Pipe B" on April 4th.

[0112] Specifically, as in the calculation of the tentative order quantity for the "leg," 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, as shown in FIG. 14, 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," and makes a tentative order for "Pipe B."

[0113] The tentative order unit 45 also calculates the predicted stock quantity for "Pipe B" on April 4, 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 4 is "25 / 4 (50 / 8)," based on the predicted stock quantity for "Pipe B" on April 3 (the previous day), and the usage quantity, order quantity, and tentative order quantity for "Pipe B" on April 4.

[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. Therefore, the order quantity for "Pipe B" on April 7 is "0," as shown in Figure 13. Therefore, if there is no tentative order for "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 tentative orders for "leg parts" are made on April 5, tentative orders for "leg parts" on April 8, and tentative orders for "Pipe B" on April 4, the estimated inventory quantity for "Pipe B" on April 7 must be calculated taking these tentative orders into account. 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. The estimated inventory quantity for "Pipe B" on April 7 is lower than the safety inventory quantity for "Pipe B," "6 (48 / 8)." Therefore, 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 multiple (integer multiple) of "1," which is the order lot number for "Pipe B," that will make the predicted 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 multiple 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 makes a tentative order for "Pipe B."

[0117] The tentative order unit 45 also calculates the predicted inventory quantity for "Pipe B" on April 7th, taking into account the calculated tentative order quantity for "Pipe B." The predicted inventory 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 inventory 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 inventory 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, using the same procedure, and makes provisional orders for these parts.

[0119] 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 the user to arrange for the production of the control item C and the components of the control item C that have been provisionally ordered, and to make arrangements for the production of the received control item C and the components of the 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.

[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 the order information 56 of the control item C and its component parts for which production arrangements have been made as forecast order information 56b in the production arrangement list 55.

[0122] Figure 15 is a diagram showing the managed item master after making production arrangements for stock production according to the second embodiment. Specifically, when the forecast production management unit 47 makes production arrangements for the "legs" and "pipe B" that were provisionally ordered as shown in Figure 14, the provisional order quantity is confirmed as the order quantity, as shown in Figure 15. The number in the provisional order quantity in Figure 14 is moved to the order quantity in Figure 15, and it can be seen that the number in parentheses in Figure 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 management 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 the management item C and the component parts of the management item C, for which production arrangements have 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 Second Embodiment] Next, a production management method of the production management system 1 according to a 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 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 control item C, the tentative order unit 45 also executes the information reference step through the calculation result display step for the components of control item C (S10 to S17 in FIG. 11). The user may check the information on the tentative orders for control item C and its components on the control item display screen 32 and manually change the tentative order quantity (S1 in FIG. 11: tentative order quantity change step).

[0127] 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 inventory quantity and other related tentative order quantities based on the changed tentative order quantity (post-update calculation step).

[0128] Furthermore, the tentative order unit 45 of the control unit 40 automatically recalculates and displays the tentative order quantities of the components of the management item C whose tentative order quantities have been changed (post-change calculation step). When the tentative order quantity of a component of the management item C is changed, the tentative order unit 45 automatically recalculates and displays the tentative order quantities of the components at a lower level than that component. Furthermore, the tentative order unit 45 redoes the tentative order for the management item C and its components using the new tentative 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 placed (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 references the updated information and automatically recalculates and displays the predicted inventory quantity and tentative order quantity (post-update calculation step). Furthermore, the tentative order unit 45 redoes the tentative order for the controlled item C and its component parts using the newly calculated tentative order quantity.

[0130] After checking the information on the provisional order, if there are no problems, 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 step). The prospective production management unit 47 accepts the 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 accepted control item C and the components of the control item C (S20 in FIG. 11: production arrangement step).

[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 production arrangements that have already been arranged.The provisional order quantity is then changed to the order quantity.The forecast production management unit 47 of the control unit 40 also registers the order information 56 for the control item C and the components of the control item C for which production arrangements have been made as forecast 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 using the production management system 1 according to the second embodiment is 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 the 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 at least to the product master 53, and 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 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 product master 53 and changes to the tentative order quantity at the time of calculation, and therefore has the advantage of being able to accurately order the managed 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, just like 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 arranging 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 quantity equal to or greater than the safety inventory quantity as the provisional order quantity. 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 according to the first embodiment, the production management system 1 according to the second embodiment is configured to be able to manage the number of uses and the predicted inventory number 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 the units used in purchasing are different, and it is possible to standardize the calculation method for determining the provisional order number, thereby offering the advantage of being able to accurately order controlled items C.

[0139] Furthermore, like the production management system 1 according to the first embodiment, the production management system 1 according to 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 enabling the controlled item C to be ordered with high 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 tentative 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 tentative order unit 45 is configured to be able to make tentative 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 tentatively 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 section 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 section 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 section 41 and the forecast production management section 47, and there is an advantage that the controlled item C can be arranged more accurately.

[0142] [Modifications] While 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 the minimum number at which the predicted stock quantity is equal to or greater than the safety stock quantity as the tentative order 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 reorder 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 will result in the predicted inventory quantity being 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 taking into account 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 number of uses and the predicted stock quantity of the control item C as fractions 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 number of uses and the predicted stock quantity of the control item C all as integers.

[0147] In the first and second embodiments described above, the production management system 1 is described as including a display unit 30 capable of displaying the predicted inventory quantity, and the display unit 30 is configured 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 limited to this. 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 tentative 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 tentative orders for the control item C and its components, and the forecast production management unit 47 is configured to make production arrangements for the tentatively 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 tentative 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 the predicted inventory quantity of the component parts of the management item C in consideration of the tentative order quantity and the predicted inventory quantity of the management item C. However, this is not limiting. The tentative order unit 45 does not have to calculate the tentative order quantity and the predicted inventory quantity of the component parts of the management item C in consideration of the tentative order quantity and the predicted inventory quantity of the management item C.

[0151] 1 Production management system 10 Production management device 20 Input section 30 Display section 32 Managed item display screen 40 Control section 41 Order management section 43 Managed item registration section 45 Tentative order section 47 Forecast production management section 50 Storage section 51 Order list 52 Order information 53 Product master 54 Product information 55 Production arrangement list 56 Arrangement information 56a Production arrangement information 56b Forecast arrangement information 57 Managed item master 58 Production management program C Managed item

Claims

1. A production management system comprising: a storage 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 the subject of forecast production as managed items; and a control unit that can set tentative order quantities for the managed items, wherein the control unit is configured to calculate a predicted inventory quantity for the managed 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.

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

3. The production management system according to claim 2, wherein the management item master is configured to be able to register the safety stock quantity of the management item, and the control unit is configured to calculate, when the predicted stock quantity before calculating the tentative order quantity is lower than the safety stock quantity of the management item, the smallest number that makes the predicted stock quantity equal to or greater than the safety stock quantity as the tentative order quantity.

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

5. A production management system according to any one of claims 1 to 4, configured to be able to manage the number of used items and the predicted inventory quantity as fractions with the number of parts obtainable from the base material as the denominator.

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

7. A production management system as set forth in any one of claims 1 to 4, wherein the control unit includes an order management unit, a tentative order unit capable of setting the tentative order quantity, and a forecast production management unit, wherein the order management unit is configured to make production arrangements for the products and parts other than the managed items and their constituent parts, the tentative order unit is configured to be able to make tentative orders for the managed items and their constituent parts, and the forecast production management unit is configured to make the production arrangements for the managed items and their constituent parts that have been tentatively ordered.

8. A production management method in which a production management device 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 subject to 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.

9. A production management program that causes a production management device having 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 subject to forecast production as managed items, and a control unit that can set tentative order quantities for the managed items to calculate a predicted inventory quantity for the managed items taking into account the tentative order quantities, and automatically recalculate the predicted inventory quantity when at least one of the product master and the tentative order quantities is changed.

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