JP2001356809A - Selling and producing and delivering system for steel sheet and steel band product and method for the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To realize short lead time production and small inventory cooperatively with the reception of a customer by setting order quantity matched with a manufacture lot and a proper manufacture starting period by each steel material unit. SOLUTION: The results of the fluctuation of a lead time from the start of manufacture to the end of manufacture and the results of a gap between a delivery deadline and an actual delivery date are stored by each same kind of specification component/delivery route unit, and a gap between the target and the results is statistically evaluated by each same kind of specification component/delivery route unit by using the result information, and the proper number of inventory dates is daily updated and set by a learning control system based on the results (423), and the contents of a proper number of inventory date setting reference are diagnosed, and an alarm is issued especially when the dissociation between the target and the results is large.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sales production and delivery system and a sales production and delivery method for a steel strip product.

[0002]

2. Description of the Related Art As a generally known form of material supply, for example, there is a fluctuation due to sales until a model change is performed at a several-year pitch, such as a steel plate for an automobile, but there are basically repeated orders. They are broadly classified into those that are used only for specific applications, such as building components and parts, and that do not have repeated orders or delivery dates. The materials, members, and parts according to the former order form are referred to as so-called "repeat products", and the materials, members, and parts according to the latter order form are referred to as so-called "spot goods".

[0003] In the case of spot products, the order quantity and delivery date are determined uniformly by the specification design of the property and the process schedule, whereas in the repeat product, although the specifications of the parts are fixed, the usage of the parts is determined. The delivery date is determined by the monthly production plan of the product using the part, and the order and production are repeated every month.

Conventionally, regarding the production of repeat products, as described in Japanese Patent No. 2847276, “Delivery time management system for coiled products”, orders for parts of the same specification are consolidated at the head office, and the same specification There is a known method in which an appropriate number of days or an appropriate stock amount is determined for each part, a shortage amount for the appropriate stock is obtained every season in light of a customer's use schedule, and a delivery date and an order amount are set.

[0005]

As described above, orders for each part of the same type of specification are collected at the head office, the appropriate stock days or the appropriate amount of stock are determined for each part of the same type of specification, and each season is determined according to the customer's use schedule. In the conventional method of determining the shortage amount for the appropriate stock and setting the delivery date and the order amount, the following methods (a) to
There is a problem listed as (d).

(A) When trying to perform production according to a customer's order, there may be a temporary excess or deficiency in terms of production capacity.

[0007] Therefore, it is common practice to have a proper product inventory, absorb excess or deficiency in production with the inventory, and aim at leveling the operation of the production line. For this reason, orders have been once collected at the head office, production capacity and order quantity are allocated, and a business step of determining a delivery date in consideration of product inventory has occurred. For this reason, a pool of seasonal orders is required in the shortest possible time, and a paper lead time of about 10 days (clerical processing waiting period: the time required from the provisional order entry to the start of production (tapping)) is required. I was

[0008] (b) In the method of calculating the shortage amount for the appropriate stock in a seasonal unit and setting it as an order amount, the production lot and the order amount cannot be matched, and a surplus product is generated or a lead time for manufacturing chance waiting. Or the inconvenience of generating

(C) Variations in the use schedule and actual results of the customer side, and variations in manufacturing, fluctuate in several months, such as fluctuations in the shipping tendency due to changes in market conditions, stability in operation and quality, and changes in product inspection standards. For each of the same type of used parts, the value varies depending on the factor. Therefore, there has been a problem that when the fixed value is set to a predetermined fixed value, the actual stock gradually deviates from the actual state.

[0010] (d) Since the delivery date is set at the seasonal pitch, the fluctuation of the customer's use schedule is reflected in the seasonal unit. It is managed redundantly with the factory,
It was an inefficient business situation.

In view of the above, the main object of the present invention is to set an order quantity consistent with a production lot for each steel material unit and an appropriate production start time, thereby achieving a short lead time linked to customer pick-up. It is an object of the present invention to provide a sales production and delivery system and a sales production and delivery method for a steel sheet steel strip product, which enables production and low inventory.

Another object of the present invention is to directly input customer's pick-up schedule information and product inventory information to a terminal device of a factory, calculate the delivery date at the factory, and optimize the product inventory by a learning control method. An object of the present invention is to provide a sales production and delivery system and a sales production and delivery method for steel strip products.

[0013]

In order to achieve the above object, a sales production and delivery system according to claim 1 updates information on a customer's scheduled delivery of a steel strip product to the latest state. A customer receipt schedule information storage means (e.g., corresponding to 412 in FIG. 2) and a sales order storage means (e.g., in FIG. 2) for storing information on orders and product specifications of steel strip products from customers. 411
), And a result information storage unit that stores the results of fluctuations in the lead time from the start of manufacturing to the completion of manufacturing, and the results of the deviation between the delivery deadline and the actual delivery date for each unit of the same type of specification / delivery route ( For example, using the result information stored in the result information storage means, the deviation between the target and the result is statistically evaluated for each component of the same specification / delivery route, and the result is evaluated. A stock days setting means (e.g., corresponding to 423 in FIG. 2) for successively updating the appropriate stock days setting criteria based on the learning control method, and a proper stock days setting criteria updated and set by the stock days setting means. (E.g., 428 in FIG. 2) is diagnosed, and a set stock days diagnosing means (for example, FIG. 2) for instructing to issue an alarm when the difference between the target and the actual exceeds a predetermined value. 425 With the corresponding), the customer receipt scheduled take-off is stored in the schedule information storage means and the scale withdrawal is calculated on the basis of the take-off performance, and / or, based on the presence or absence of the repetition of manufacture -
A production order amount determining means (e.g., corresponding to 421 in FIG. 2) for determining a production order amount per one time at which the distribution cost is minimized, and a work-in-progress inventory, a product inventory, and a customer's schedule for each production order. The estimated date of stockout occurrence is calculated, and based on the estimated date of stockout occurrence, the delivery preparation completion reference date, the production completion reference date, and the production process Reference date calculation means (e.g., corresponding to 422 in FIG. 2) for calculating all or some of the reference dates, the production start instruction reference dates.
And production order storage means for inputting output information from the reference date calculation means and storing information relating to production management including at least one of a product specification, a delivery deadline, and a production completion deadline (for example, FIG. 426) and information from the production order storage means, and a production lot consolidation means (for example, a production lot consolidation means for consolidating production orders within a range satisfying the production completion reference date according to the lot of the production process)
2 corresponds to 431 in FIG. 2), based on the output of the manufacturing lot aggregating means, extracts a manufacturing order having the manufacturing start instruction reference date matching the manufacturing start instruction period of the day, and instructs the start of manufacturing. Instruction means (for example, 43 in FIG. 2)
2,433).

According to a second aspect of the present invention, there is provided the sales / production / delivery system according to the first aspect, wherein the delivery includes any one of a proper stock crack, a monthly difference in the scheduled delivery, and a difference between the scheduled delivery and the actual result. An alarm transmission unit (corresponding to, for example, 440 in FIG. 2) is provided which captures a change that causes a problem and transmits an alarm to the relevant departments.

According to a third aspect of the present invention, in the sales / production / delivery system according to the first aspect, the sales order and the production order, the work in progress, and the actual product are grouped by product specification, production specification, and transportation route. The sales order storage means, the customer pickup schedule information storage means,
Grouping processing means (e.g., for outputting corresponding data) to the performance information storage means and inventory database storage means (e.g., corresponding to 413 in FIG. 2)
(Corresponding to 410 in FIG. 2).

According to a fourth aspect of the present invention, in the sales, production and delivery system according to the first aspect, an allowable range of a reference date for completion of delivery preparation is set, and products having the same transport route are sent to the distribution base within the allowable range. By consolidating and transporting, the product transport lot is optimized in relation to the delivery preparation completion date, and the loading rate per transport, that is, the product quantity / maximum loading capacity is increased.

According to a fifth aspect of the present invention, in the sales, production and delivery system according to the fourth aspect, when optimizing the product transport lot, the customer accepts a customer upon adding an order specification (for example, corresponding to 350 in FIG. 1). An allowable range of the unit weight of the product in consideration of the restrictions is set, and the unit for determining the unit weight of the product is within the allowable range by using the unit weight achievement evaluation formula in the production order amount determining means (e.g., corresponding to 421 in FIG. 2). Is controlled to maintain a high position.

According to a sixth aspect of the present invention, in the sales, production and delivery system according to the fourth aspect, in optimizing the product transport lot, the production lot aggregating means (eg, 431 in FIG. 2) is used. By assembling the products of the rare transportation route on a transport lot basis based on the delivery preparation completion reference date and issuing a production start instruction, product assortment according to the transport lot is guaranteed.

According to a seventh aspect of the present invention, there is provided a sales production / delivery method, comprising:
A customer pickup schedule information storage step (e.g., corresponding to 412 in FIG. 2) for storing while updating to the latest state;
A sales order storage step (for example, corresponding to 411 in FIG. 2) for storing information on ordering and product specification of a steel strip product from a customer, a track record of lead time fluctuation from the start of production to the completion of production, A result information storing step of storing the results of the deviation between the delivery deadline date and the actual delivery date for each of the same specification parts / delivery route units (for example, 4 in FIG. 2)
14), and using the performance information stored in the performance information storage step, statistically evaluates the difference between the target and the performance for each component of the same kind / delivery route, and learns based on the performance. A stock days setting step (e.g., corresponding to 423 in FIG. 2) for successively updating the appropriate stock days setting criterion by the control method, and an appropriate stock days setting criterion updated and set in the stock days setting step (for example, FIG. 2) 428), and a set stock days diagnosis step (e.g., corresponding to 425 in FIG. 2) for instructing to issue an alarm when the difference between the target and the actual exceeds a predetermined value. Based on the pick-up schedule stored in the customer pick-up schedule information storage step and the pick-up scale calculated based on the pick-up results, and / or based on the presence or absence of repeatability, A production order quantity determining step (e.g., corresponding to 421 in FIG. 2) for determining a production order quantity per production that minimizes manufacturing / distribution costs; and taking in-process inventory, product inventory, and customers for each production order A predicted shortage occurrence date is calculated from the schedule, and the delivery preparation completion reference date, the production completion reference date,
A reference date calculation step (e.g., corresponding to 422 in FIG. 2) for calculating all or some reference dates for each manufacturing process processing reference date, manufacturing start instruction reference date, and information calculated in the reference date calculation step. A manufacturing order storage step (e.g., corresponding to 426 in FIG. 2) for inputting and storing information related to production management including at least one of a product manufacturing specification, a delivery deadline, and a manufacturing completion deadline; A production lot consolidation step (for example, corresponding to 431 in FIG. 2) of reading stored information by step and consolidating production orders within a range satisfying the production completion reference date according to a lot of a production process; Based on the output of the step, a production order having the production start instruction reference date matching the production start instruction period of the day is extracted, and the production is started. Production start instruction step of instructing (e.g., corresponding to 432 and 433 in FIG. 2) is obtained by and a.

[0020]

Embodiments of the present invention will be described below in detail with reference to the drawings.

FIG. 1 is an overall configuration diagram showing a sales production and delivery system of a steel strip product to which the present invention is applied, and a relationship between a customer and a trading company related to the sales production and delivery system. In the figure, reference numeral 2 denotes the entire customer who is a customer. Here, reference numeral 110 denotes a customer ordering unit, and 120 denotes an internal unit. The ordering unit 110 and the unofficial unit 120 perform a general ordering function and an unofficial unit function, and a detailed description thereof will be omitted.

Reference numeral 4 denotes the entire trading company, a sales order input unit 210 for outputting a sales order to the factory, and a scheduled input unit 220 for outputting scheduled information to the factory.
And an alarm receiving unit 230 issued from the factory. In addition, regarding the alarm issued from the factory side,
Details will be described later.

FIG. 6 shows the overall configuration of a factory having the sales production delivery system 10 according to the present embodiment. Where 3
Reference numeral 10 is an order approval unit for receiving a sales order from a trading company.
350 is an order specification adding unit that supplies sales order information to the sales production delivery system 10, 360 is a stock information editing unit that supplies inventory information to the sales production delivery system 10, 370
Reference numeral denotes a production collection result collection unit that supplies production collection result information to the sales production delivery system 10. Further, the sales production / delivery system 10 includes a production planning section 510 and an operation command section 61.
0, a delivery management unit 710, and a shipping unit 810.

FIG. 2 is a detailed internal configuration diagram of the sales, production and delivery system 10 shown in FIG. In this figure, 41
Numeral 0 denotes a grouping processing unit for inputting the sales order information, the pick-up schedule information, the stock information, and the production pick-up result information already described with reference to FIG. 1 and executing a grouping process described in detail later (see FIG. 5). I do. This grouping processing unit 4
Reference numeral 10 includes an arithmetic processing unit (not shown) and various memories, and the arithmetic processing unit executes a processing operation in accordance with a processing procedure stored in a specific memory in advance.

Reference numeral 411 denotes a sales order database (hereinafter abbreviated as DB) storage unit, which stores information as exemplified in FIG. 3A.

Reference numeral 412 denotes a pick-up schedule DB storage unit, which stores information as exemplified in FIG. 3B.

Reference numeral 413 denotes an inventory DB storage unit, which stores information as exemplified in FIG.

Reference numeral 414 denotes a production pick-up result DB storage unit, which stores information as exemplified in FIG.

Reference numeral 426 denotes a manufacturing order DB storage unit.
Information as exemplified in FIG. 4B is stored.

Reference numeral 427 denotes a diagnostic information DB storage unit, which stores information as exemplified in FIG.

Reference numeral 428 denotes a stock days setting reference storage unit which stores the processing results of the stock days setting processing unit 423 described later in detail.

Reference numeral 421 denotes a production order amount determination processing unit 422
Is a reference date calculation processing section, 423 is the above-mentioned stock days setting processing section, 424 is a delivery diagnosis processing section, 425 is a stock days diagnosis processing section, 431 is a production lot consolidation processing section, 432 is a capacity verification processing section, and 433 is production start. Selection processing unit, 440
Is an alarm transmission processing unit, each of which has a processing unit and various memories (not shown), and each processing unit executes a processing operation according to a processing procedure stored in a specific memory in advance. . It is also possible to adopt a configuration in which the processing in each of the above-described processing units and the above-described grouping processing unit 410 is executed by a single central processing unit.

Next, the operation of each processing unit shown in FIG. 2 will be sequentially described.

FIG. 5 exemplifies a grouping key for explaining the operation of the grouping processing section 410. The grouping key is a word representing the type (sales / production) / transportation route of the steel material. The grouping processing unit 410 determines the above-mentioned grouping key and adds the key information in order to group the sales order information, pick-up schedule information, stock information, and production pick-up result information with a common mesh representing the type and transport route of the steel material. .

The sales order information is issued when new sales order information is generated, and is stored in a master table (not shown). Further, the pickup schedule information is for searching the master table when creating the pickup schedule information, and is created using a mesh of key information. Then, key information is passed in the order of sales order information → manufacturing order information → stock actual item information → stock information, and grouping is performed according to the key. Further, the grouping is performed in accordance with the key information held in the above-mentioned production order information / stock actual item information based on the production pickup result information.

Next, referring to FIGS. 6 and 7, the learning control operation of the stock days setting processing section 423 shown in FIG. 2 will be described. Here, FIG. 6A exemplifies information stored in the production take-off record DB storage unit 414 (see FIG. 2) as an input parameter used in the learning control.

FIG. 6B is a diagram for explaining the definition of the "stock days" used in the present embodiment. In other words, the product stock days are separated into the safety stock part for the manufacturing variation and the safety stock part for the manufacturing variation, and the safety stock part for the manufacturing variation and the safety stock part for the manufacturing variation for each grouping key (steel code). Set. In addition, when setting the reference date, the number of days of stock is traced back from the delivery date and each reference date is set.

According to the learning control method in the stock days setting processing unit 423, the production lead time fluctuation results (= delivery preparation completion reference date−storage results date) and the pickup fluctuation results (= (Delivery delivery date-pickup date) Then, every time 10 new performance values are generated, the manufacturing variability and the pick-up variability are calculated based on the 50 pieces of performance information in the new order (the calculation method will be described later with reference to FIG. 7). The obtained calculated values are classified into large, medium, and small, respectively (thresholds are set by reference).

Then, based on the large / medium / small judgment of the manufacturing variation / take-up variation, the stock days setting standard is corrected. Specifically, when it is large: increase the stock days at a constant pitch. Middle: The value is the same as before. When small: Reduce the number of stock days at a constant pitch.

FIG. 7 is an explanatory diagram showing the concept of setting the number of days of stock according to the present embodiment in more detail. It is preferable to consider the change of the stock days (that is, learning control) in two ways: (1) delivery delivery date to delivery preparation reference date, and (2) delivery preparation completion reference date to storage reference date. .

(1) Delivery delivery date to delivery preparation completion reference date: When pick-up variation <the number of days of stock update determination is reduced (take-back) → set to “set value + x days”.

When the stock days update determination is reduced (takeover) ≦ takeover variation ≦ the stock days update determination is increased (takeover) → “set value”.

When the variation in pick-up is greater than the stock days update judgment (take-up) → Set “set value−x days”.

(2) Regarding the delivery preparation reference date to the storage reference date: when manufacturing variation <the number of inventory days update determination is reduced (manufacturing) → set to “set value + y day”.

When the number of inventory days update determination is reduced (manufacturing) ≦ manufacturing variance ≦ the number of inventory days update determination is increased (manufacturing) → set to “set value”.

Manufacturing Variation> Inventory Days Update Judgment Increase Side (Manufacturing) → Set as “set value−y day”.

Each parameter is uniformly set by a grouping key (steel material code).

FIG. 7 shows an image of the setting of the number of days of stock obtained from the delivery date to the limit date of the shipping order obtained in this way.

Next, a method of calculating the pick-up variation and the manufacturing variation used in the learning control will be described.

In the present embodiment, every time ten incoming and outgoing records are generated, calculation is performed on the latest 50 incoming and outgoing and receiving results. At this time, with respect to the pick-up variance, the pick-up variance = the average of (delivery date-pick-up result) +
It is the standard deviation of (delivery date-actual delivery). However, delays are excluded from the calculation.

The manufacturing variance is defined as the average of (manufacturing variance = (base date of completion of delivery preparation−recording of actual receipt)) + standard deviation of (base date of completion of delivery preparation−accumulation of storage). However, the preceding is excluded from the calculation.

Next, referring to FIG. 2 again, the storage process (called step S1) in the production pick-up result DB storage unit 414, the calculation process (called step S2) in the stock days setting processing unit 423, the inventory The storage process (referred to as step S3) in the number-of-days setting reference storage unit 428 will be described.

In step S1, each time a product is received and picked up, the production lead time fluctuation result (= delivery preparation completion reference date-receipt actual date) and pickup fluctuation result (= delivery date- (Collection date) value is cumulatively stored.

In step S2, the stock days setting processing unit 423 calculates the manufacturing variance and the pick-up variance as described above, based on the 50 newest result information each time 10 new result values are generated. I do. Then, the calculated values are classified into large, medium, and small, respectively (thresholds are set in advance with reference).

In step S3, the manufacturing variation
Based on the large, medium, and small determination of the pick-up variation, the stock days setting standard is corrected and stored in the stock days setting standard storage unit 428. That is, when the judgment is large, the number of days of stock is increased at a constant pitch, and when the judgment is medium, the value is the same as before,
When the judgment is small, the stock days are reduced at a constant pitch.

FIG. 8 is an explanatory diagram of the operation of the manufacturing order amount determination processing section 421 shown in FIG. The horizontal axis of the table shown in the upper part of the figure represents the repeatability of the take-off in grouping key units. The vertical axis in the table indicates the size of the collection.

The policy for determining the production order here is as follows. 1) When there is repeatability and the take-up scale is large (the monthly take-up amount is equal to or more than the upper limit of the slab design), the policy is to "maximize the unit weight achievement" (that is, aim at improving the production efficiency). 2) If there is a repeatability and the collection size is medium (the monthly collection amount is less than the upper limit of the slab design / more than the lower limit of the slab design), the policy is to “maximize the unit weight of the product” (that is, increase the inventory). Pursue the next best efficiency in production and transportation while deterring). 3) If the repeatability is low or the take-up scale is small (the monthly take-up amount is less than the lower limit of the slab design), the policy is to minimize the surplus generation amount.

As for the unit weight achievement index, the unit weight of the slab and the unit weight of the product are not necessarily synchronized as illustrated in the lower part of FIG. 8, and either of the slab priority and the product priority measures is advantageous. Since there is a case-by-case basis, which is more advantageous is evaluated for each steel material group using the evaluation formula.

FIG. 9 is a flowchart showing a processing procedure for determining the production order amount.

First, in step S10, the sales order specification adding section 350 is executed in accordance with the specifications of the standards, dimensions, and passing processes.
In FIG. 1 (see FIG. 1), a production order quantity candidate in the case of the slab upper limit and the case of the product single weight upper limit is calculated.

In step S11, the calculated data is stored in the sales order DB storage unit 411 (see FIG. 2).

In step S12, the data is extracted from the sales order DB storage unit 411.

In parallel with the above steps S10 to S12, in step S13,
12 (refer to FIG. 2), the data to be collected is read.

In step S14, the repeatability / collection scale for each grouping key (steel material code) is calculated based on the scheduled collection data from the scheduled DB storage unit 412.

In step S15, a production order setting policy is determined based on the repeatability and the take-back scale, and a production order amount is determined based on a unit weight achievement evaluation formula or the like.

In step S16, the production order amount is output from the production order amount determination processing section 421.

FIG. 10 shows the reference date calculation processing section 422 (FIG. 2).
FIG. 4 is an explanatory diagram showing a concept for calculating a reference date in (see). In this figure, the period between tapping and delivery is classified into periods according to the respective characteristics. Then, the stock days setting criteria are classified into the following three groups based on this feature and created. (First group) Variation in manufacturing: Set the required number of days for each passing step. (Second group) Variation in transportation: Variations in transportation are characterized by transportation flights and delivery locations. (Third group) Variations in customer pickup: Variations in customer pickup are characterized by customers and delivery locations.

FIG. 11 shows the reference date calculation processing unit 422 (FIG. 2).
2 is a flowchart showing a processing procedure in the second embodiment.

In step S20, the sales order specification read from the sales order DB storage unit 411 is input via the production order amount determination processing unit 421.

In step S 21, the stock days setting reference is input from the stock days setting reference storage unit 428.

In step S22, the number of days of stock for each reference day is assigned from the number of days of stock setting reference based on the sales order specification to set the number of days of stock.

In step S23, the inventory DB storage unit 41
3 is input via the production order amount determination processing unit 421.

In step S 24, the scheduled take-out data read out from the scheduled take-back DB storage unit 412 is input via the production order amount determination processing unit 421.

In step S25, the grouping key
For each (steel material code) unit, the expected stockout date is calculated from the stock and the scheduled pick-up, and this is used as the delivery date.

In step S26, the number of days of stock is traced in order from the delivery date to set a reference date.

In step S27, the calculated reference date is stored in the manufacturing order DB storage unit 426.

The reference date stored in this way is used not only for specifying the manufacturing target period in the manufacturing lot consolidation processing unit 431 (see FIG. 2), but also for the advance delay evaluation in the delivery management unit 710 (FIG. 1). Can be.

FIG. 12 is an explanatory diagram showing how to summarize the production lots in the production lot aggregation processing section 431 shown in FIG. In the example shown in this figure, those having the same processing conditions are processed collectively for the ones for which the processing conditions are strongly regulated in each manufacturing process / transportation route. Each input parameter and the production order information corresponding to each input parameter are as follows.

Input parameters [manufacturing order information] tapping [for lots of rare component systems, lots are collected according to tapping pitch. For example, steel grades that only have a monthly chance are covered up to one month ahead on the tapping date. ] Plating [If the plating type is rare, make lots according to the plating pitch. For example, a plating type that only has a chance of once a month covers the plating base date one month ahead. ] Transport [If the target volume is small by transport route, lots are collected at a pitch that matches the transport lot determined by the capacity of the transport equipment. For example, a transportation route that only has a chance once a month should be covered up to the one month ahead of the delivery ready base date. ]

FIG. 13 shows the capability verification processing unit 4 shown in FIG.
FIG. 32 is an explanatory diagram showing a procedure of a manufacturing start instruction by a manufacturing start selection unit 32 and a manufacturing start selection processing unit 433. In the present embodiment, making a tapping request on the day or extracting a production order to be assigned to the material on the day is called a production start instruction. The input parameters required to obtain the above manufacturing start instruction are
Production order information and equipment operation schedule.

In FIG. 13, when the lot is not put together, a production start instruction is issued on the day according to the tapping reference date or the material allocation reference date of the production order and within a range that satisfies the capacity frame of the planned period. In addition, if there is a lot consolidation, production starts on the same day according to the tapping date or the material allocation reference date of the production order, within the range that satisfies the capacity quota of the planning target period for those that fall under the lot consolidation period. Make instructions.

The operation schedule instruction processing section 434
In (see FIG. 2), a production order to be planned on the day is provisionally determined, and the load of each production process is evaluated. The capacity of each manufacturing process is determined from the operation schedule. Further, the capacity and load of each manufacturing process are compared, and a manufacturing order frame within a range satisfying the capacity frame is set. Thus, a production start instruction is issued based on the production order frame within the range satisfying the capacity frame.

FIG. 14 is an explanatory diagram of the operation of the stock days diagnosis processing unit 425 shown in FIG. Input data necessary for performing the stock days diagnosis is read from the stock days setting reference storage unit 428. Then, for each grouping key (steel material code) unit, the correction value set by the stock days setting processing unit 423 is searched, and the correction value that is corrected to the increased side is extracted. As the output data of the stock days diagnosis processing unit 425, the stock days correction value is written to the diagnosis information DB storage unit 427.

As a result, the problem can be extracted by searching the diagnostic information DB storage unit 427 in the order of the correction value and the size of the correction value.

FIGS. 15 and 16 are explanatory diagrams showing the concept and operation of the delivery diagnosis in the delivery diagnosis processing section 424 (see FIG. 2). The input data necessary for the delivery diagnosis in the present embodiment is a manufacturing order D
Read from the B storage unit 426. Then, for each grouping key (steel material code), calculate the product inventory, product inventory + work-in-process inventory, and the total unshipped remaining amount of the production order. Is determined. The determination result (output data) is the diagnostic information D
Write to the B storage unit 427.

FIG. 15 shows a diagnosis method in the case where the product stock is insufficient. For example, a diagnosis result as shown in FIG. 17A is obtained. FIG. 16 shows a diagnosis method when the product + work in stock is insufficient or the unshipped inventory is insufficient. For example, a diagnosis result as shown in FIG. 17B is obtained. Then, a problem can be extracted based on these diagnosis results.

FIG. 18 is an explanatory diagram of the operation of the alarm transmission processing section 440 shown in FIG.

Input data necessary for processing for generating an alarm is read from the diagnostic information DB storage unit 427. Then, as a result of the judgment of the appropriate stock days in the grouping key (steel material code) unit, when the product stock is less than two weeks of the scheduled pick-up amount, the alarm information is transmitted to the sales / trading company.

In “Case 1” shown in FIG. 18, the picked-up amount has exceeded the initial schedule, and even if the apparent product stock is small, the total of the picked-up amount and the stock amount is covered up to two weeks ahead of the scheduled time. If so, there is no alarm.
On the other hand, if not covered, an alarm is issued.

In “Case 2” shown in FIG. 18,
Conversely, if the picked-up amount is short, or if the total of the picked-up amount and the stock amount cannot be covered up to two weeks ahead even if the apparent product inventory is large, an alarm is issued. On the other hand, if it is covered, there is no alarm.

Next, the relationship between the delivery diagnosis and the stock days diagnosis will be described.

[0092] The delivery diagnosis is for comparing the stock and the pick-up schedule to determine whether or not the delivery is within an appropriate range, thereby preventing the occurrence of a delivery trouble. On the other hand, the stock days diagnosis extracts items having particularly large lead times and items having large variations so that a product can be produced with an appropriate lead time. In other words, the purpose is to clarify the problem of manufacturing and the problem of variation in customer pick-up.

Further, the alarm is generated in the delivery diagnosis every day at the time of comparing the pick-up schedule with the stock. On the other hand, the alarm is generated in the stock days diagnosis at the time when the stock days are set each time, for example, ten items are collected in each grouping key (steel material code).

(Summary) In the present embodiment described above,
Regarding the four problems (a) to (d) described in the section of “Problems to be Solved by the Invention”, the present invention provides a special solution as described below.

(A) Reduction of paper lead time.

Information on the inventory of steel sheet and steel strip products, which is collected and updated through the inter-company network, and on the schedule of customer pick-up, is directly connected to the factory, the manufacturing order is extracted at the factory, and the work in process for each manufacturing order is performed. Based on the inventory / product inventory and the customer's scheduled pick-up, the expected date of missing items is calculated, and based on the estimated date of missing items, based on the appropriate stock days setting standard, the date of completion of delivery preparation, the date of production completion, By calculating the manufacturing process processing reference date / manufacturing start instruction reference date, it is possible to extract the production order having the production start instruction reference date that matches the production start instruction period of the day, and to instruct production start. Since it is possible to use the latest information every day to determine the start of production while matching the order volume and production capacity, it is not necessary to pool orders for about 10 days at the head office. Now, it is possible to reduce the paper lead-time.

(B) Matching of production lot and order quantity.

Based on the size of the collection and the presence or absence of repeatability calculated from the planned collection and results, the production order quantity per production that minimizes the production and distribution costs is determined, and the production completion reference date is adjusted according to the lot of the production process. Consolidate production orders within a satisfactory range and consolidate production lots to instruct production start, and set an allowable range for the base date of the completion of delivery preparation, and send products with the same transport route to distribution centers such as service centers within the allowable range. By consolidating and transporting products, it is possible to optimize product transport lots in relation to the delivery preparation completion reference date, so that it is possible to match production lots and order quantities, It is possible to reduce occurrences and occurrences of waiting for manufacturing chances.

(C) Setting of the appropriate stock days.

The results of fluctuations in lead time from the start of manufacturing to the completion of manufacturing and the results of deviations between the delivery deadline and the actual delivery date are stored for each unit of the same type of specification / delivery route, and the performance information is used. Statistical evaluation of the difference between the target and the actual results for each component / delivery route of the same type, and i) based on the actual results, update and set the appropriate stock days daily using the learning control method: ii) Set the appropriate stock days Diagnose the contents of the standards and, especially for those with a large discrepancy between the target and the actual results, send an alarm: In this way, promote the investigation and improvement of abnormal ones without increasing the discrepancy between the stock days setting and the actual situation Thereby, the stock days can be kept in a good state.

(D) Dealing with expected fluctuations in customer usage and managing duplication of sales / trading companies and factories.

The production order is extracted at the factory, and changes that cause problems in delivery, such as appropriate inventory cracking, monthly differences in scheduled pick-up, and deviations between the scheduled pick-up and actual results, are sent to relevant departments as alarms. Sales and trading companies can utilize the delivery diagnostic information transmitted from the factory as long as the change in the customer's usage schedule is promptly notified to the factory, eliminating duplication of product progress management work. . In other words, it is possible to eliminate duplication of work by enhancing the delivery diagnosis function on the factory side.

[0103]

As described above, according to the present invention, by setting the order quantity matched to the production lot and the appropriate production start time for each steel material unit, the short lead time production linked with the customer pick-up is achieved. And low inventory can be made possible.

Further, according to the present invention, the information on the schedule to be picked up by the customer and the information on the product inventory are directly input to the terminal device of the factory, the delivery date is calculated at the factory, and the product inventory is optimized by the learning control method. be able to.

[Brief description of the drawings]

FIG. 1 is an overall configuration diagram illustrating a relationship between a sales production and delivery system of a steel sheet steel strip product to which the present invention is applied and customers and trading companies related to the sales production and delivery system.

FIG. 2 is a detailed internal configuration diagram of the sales production delivery system 10 shown in FIG.

FIG. 3 is an explanatory diagram showing a specific example of data stored in each database (DB) storage unit.

FIG. 4 is an explanatory diagram showing a specific example of data stored in each database (DB) storage unit.

FIG. 5 is an explanatory diagram exemplifying a grouping key for explaining an operation of a grouping processing unit 410;

FIG. 6 is an explanatory diagram of a learning control operation by the stock days setting processing unit 423.

FIG. 7 is an explanatory diagram of a learning control operation performed by a stock days setting processing unit 423.

FIG. 8 is an explanatory diagram of the operation of the production order amount determination processing unit 421.

FIG. 9 is a flowchart showing a processing procedure for determining a production order amount.

FIG. 10 is an explanatory diagram showing a concept for calculating a reference date in a reference date calculation processing unit 422.

11 is a flowchart illustrating a processing procedure in a reference date calculation processing unit 422. FIG.

FIG. 12 is an explanatory diagram showing how to summarize production lots in a production lot aggregation processing unit 431.

FIG. 13 is an explanatory diagram showing a procedure of a production start instruction by a capability verification processing unit 432 and a production start selection processing unit 433.

FIG. 14 is an explanatory diagram of the operation of the stock days diagnosis processing unit 425.

FIG. 15 is an explanatory diagram showing the concept and operation of the delivery diagnosis (diagnosis when the product inventory amount is insufficient) in the delivery diagnosis processing unit 424.

FIG. 16 is an explanatory diagram showing the concept and operation of delivery diagnosis (diagnosis in a case where product + work in stock or shortage of unshipped stock is insufficient) in a delivery diagnosis processing unit 424.

FIG. 17 is an explanatory diagram showing an example of a delivery diagnosis result.

FIG. 18 is an explanatory diagram of the operation of the alarm transmission processing unit 440 shown in FIG. 2;

[Explanation of symbols]

2 Customer 4 Trading company 6 Factory having sales production and delivery system 10 according to the present embodiment 310 Order acceptance unit 350 Order specification adding unit 360 Inventory information editing unit 370 Production collection result collection unit 410 Grouping processing unit 411 Sales order DB (database) Storage unit 412 Collection scheduled DB storage unit 413 Inventory DB storage unit 414 Production collection actual DB storage unit 426 Manufacturing order DB storage unit 427 Diagnostic information DB storage unit 428 Inventory days setting reference storage unit 421 Manufacturing order amount determination processing unit 422 Reference date calculation Processing unit 423 Inventory days setting processing unit 424 Delivery diagnosis processing unit 425 Inventory days diagnosis processing unit 431 Manufacturing lot aggregation processing unit 432 Capacity verification processing unit 433 Manufacturing start selection processing unit 440 Alarm transmission processing unit

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Takao Yabuuchi 2-3-2 Uchisaiwaicho, Chiyoda-ku, Tokyo Kawasaki Steel Corporation (72) Inventor Hiroshi Kondo 2-3-2 Uchisaiwaicho, Chiyoda-ku, Tokyo (72) Inventor Hiromune Takaoka 2-3-2 Uchisaiwai-cho, Chiyoda-ku, Tokyo Kawasaki Steel Corporation (72) Inventor Michio Mori 1-chome Mizushima Kawasaki-dori, Kurashiki City, Okayama Prefecture Kawasaki Steel Corporation Mizushima Works (72) Inventor Kazuyuki 1-chome, Mizushima Kawasaki-dori, Kurashiki City, Okayama Pref. BB64 BB77

Claims (7)

[Claims] Claims: 1. A customer pick-up schedule information storage means for storing information on a customer pick-up schedule relating to a steel strip product while updating the information to the latest state, and ordering and product specification of the steel strip product from the customer. Sales order storage means for storing information on the related products, and the results of fluctuations in lead time from the start of production to the completion of production, and the results of deviations between the delivery deadline date and the actual delivery date are stored for each part of the same type of specification / delivery route Performance information storage means, using the performance information stored in the performance information storage means, statistically evaluate the difference between the target and the performance for each of the same specification parts / delivery route, based on the performance, learning A stock days setting means for successively updating the appropriate stock days setting standard by the control method, and diagnosing the contents of the appropriate stock days setting standard updated and set by the stock days setting means, and determining a target and an actual result. Calculated based on a set stock days diagnosis means for instructing an alarm transmission for a product whose separation exceeds a predetermined value, and a pick-up schedule stored in the customer pick-up schedule information storage means and a pick-up result thereof. A production order quantity determining means for determining a production order quantity per production which minimizes production / distribution cost based on a pickup scale and / or a repeatability; and a work in process inventory and a product inventory for each production order. The estimated date of shortage is calculated from the customer's scheduled delivery, and based on the estimated date of shortage, based on the appropriate date-of-stock setting standard updated by the date-of-stock setting means, the standard date of completion of delivery preparation, the standard of production completion A reference date calculating means for calculating all or some reference dates, a reference date for each manufacturing process, a reference date for production start, and output information from the reference date calculating means A production order storage means for storing information relating to production management including at least one of a product specification, a delivery deadline, and a production completion deadline; and information from the production order storage means, and A production lot aggregating means for aggregating the production order within a range satisfying the production completion reference date in accordance with the lot, and a production start instruction standard adapted to a production start instruction period of the day based on an output of the production lot aggregating means. A production start instructing means for extracting a production order having a date and instructing a start of production. 2. The sales / production / delivery system according to claim 1, further comprising a change in a delivery that hinders the delivery, including any of an appropriate stock breakage, a monthly difference in the scheduled delivery, and a difference between the scheduled delivery and the actual result. And a system for sales, production and delivery of steel strip products, which comprises alarm transmission means for transmitting alarms to the relevant departments. 3. The sales order storage system according to claim 1, wherein the sales order and the production order, the work in process, and the actual product are grouped according to a product specification, a manufacturing specification, and a transportation route. Means for producing, selling, and delivering steel strip products characterized by comprising grouping processing means for outputting respective corresponding data to the means for storing customer pickup schedule information, the performance information storing means, and the inventory database storing means. system. 4. The sales, production and delivery system according to claim 1, wherein an allowable range of a reference date for completion of delivery preparation is set, and products having the same transport route are aggregated and transported to the distribution base within the allowable range. In this way, product transport lots are optimized in relation to the delivery preparation completion deadline, and the loading rate per transport, that is, the product volume divided by the maximum loading volume, is increased. system. 5. The sales, production and delivery system according to claim 4, wherein, in optimizing the product transport lot, a permissible range of a unit weight of a product is set in consideration of a customer acceptance constraint when an order specification is added, and the production order quantity is set. A sales production and delivery system for a steel strip product, wherein the determining means uses a unit weight achievement evaluation formula to control the unit weight achievement to be maintained at a high level within an allowable range. 6. The sales production / delivery system according to claim 4, wherein, in optimizing the product transport lot, the production lot consolidating means supplies a rare transport route product to a delivery preparation completion reference date for each transport lot unit. A production and delivery system for steel strip products that guarantees product assortment according to the transport lot by issuing a production start instruction based on the aggregation. 7. A customer pick-up schedule information storing step of storing information on a customer pick-up schedule relating to a steel strip product while updating it to the latest state, and ordering and specification of the steel strip product from the customer. Sales order storage step that stores information about the related products, the actual results of fluctuations in the lead time from the start of production to the completion of production, and the actual results of deviations between the delivery deadline date and the actual delivery date are stored for each unit of the same kind of specification / delivery route Using the performance information storage step and the performance information stored in the performance information storage step, statistically evaluating the deviation between the target and the performance for each of the same specification parts / delivery route, and performing learning control based on the performance. A stock days setting step for sequentially updating the appropriate days of supply setting standard according to the method; and A set stock days diagnosis step for instructing to issue an alarm for a difference between the target and the result exceeding a predetermined value; a pick-up schedule stored in the customer pick-up schedule information storing step; A production order amount determining step of determining a production order amount at which production / distribution cost is minimized based on a pick-up scale calculated based on and / or repeatability, and for each production order Calculate the expected shortage date from the in-process inventory, product inventory, and the scheduled pick-up by the customer, and complete the preparation for delivery from the predicted shortage date based on the appropriate stock days setting standard updated in the stock days setting step. Reference date calculation step for calculating all or some reference dates, reference dates for production, reference dates for each manufacturing process, reference dates for production start instructions A production order storage step of inputting calculation information in the reference date calculation step and storing information related to production management including at least one of a product specification, a delivery deadline, and a production completion deadline; and the manufacturing order storage. A production lot aggregation step of reading the storage information by the step and aggregating the production order within a range satisfying the production completion reference date according to the lot of the production process; and a production start instruction of the day based on the output of the production lot aggregation step. A production start instruction step of extracting a production order having the production start instruction reference date suitable for a period and instructing a start of production, comprising the steps of: