Production planning apparatus and production planning method

• US 10,037,018 B2
• Filed: 01/27/2016
• Issued: 07/31/2018
• Est. Priority Date: 03/26/2015
• Status: Active Grant

• Current Assignee: Hitachi, Ltd.
• Original Assignee: Hitachi, Ltd.
• Inventors: Nomoto, Tazu, Uozaki, Masayasu
• Primary Examiner(s): Patel, Ramesh
• Application Number:
  US15/007,449
• Publication Number:
  US 20160282844A1
• Time in Patent Office: 916 Days
• CPC Class Codes: G05B 19/406 characterised by monitoring or safety G05B19/19 takes precedence
• CPC Class Codes: G05B 2219/33064 Manufacturing planning and control agent and domain blackboards
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/06395 Quality analysis or management
• CPC Class Codes: G06Q 10/067 Enterprise or organisation modelling

Abstract

Provided is a production planning apparatus including: a storage unit configured to store: actual performance information on a resource required for production; a planning master including a plan of a resource required for work of the production; and a planning parameter including a variable required for a production plan; a parameter generation processing unit configured to change the plan of the resource required for the work, which is included in the planning master, based on a difference between the plan of the resource, which is included in the planning master, and actual performance of the resource required for the production, which is included in the actual performance information, and change the planning parameter based on how greatly the planning master is changed; and a production plan processing unit configured to calculate a production plan that uses the planning master and the planning parameter.

Claims

1. A production planning apparatus, comprising:

a storage unit configured to store;

actual performance information on a resource required for production;

a planning master including a plan of a resource required for work of the production, the plan of the resource including a percent defective of an item specifying a product or a part of the product to be produced under the production; and

a planning parameter including a variable required for a production plan, the planning parameter including information specifying a safety stock which is information specifying a safety stock quantity of the item, the safety stock being set in preparation for deterioration of the percent defective of the item;

a parameter generation processing unit configured to change the plan of the resource required for the work including the percent defective of the item, which is included in the planning master, based on a difference between the plan of the resource, which is included in the planning master, and actual performance of the resource required for the production, which is included in the actual performance information, and change the planning parameter including the information specifying the safety stock based on how greatly the planning master is changed; and

a production plan processing unit configured to calculate a production plan that uses the planning master and the planning parameter.

2. A production planning apparatus according to claim 1,

wherein the actual performance information includes information specifying an input quantity for production and a completed quantity,

wherein the percent defective included in the planning master is a planned percent defective, and

wherein the parameter generation processing unit is further configured to use the input quantity for production and the completed quantity, which are included in the actual performance information, to calculate an actual value of a percent defective of the item, change the planned percent defective of the item included in the planning master based on a difference between the actual value and the planned percent defective included in the planning master, and change the information specifying the safety stock based on how greatly the planned percent defective included in the planning master is changed.

3. A production planning apparatus according to claim 1,

wherein the actual performance information includes information specifying a production quantity and a period of time required for production,

wherein the planning master includes a work time, and

wherein the parameter generation processing unit is further configured to change the work time included in the planning master based on a difference between an actual value of the work time, which is calculated based on the production quantity and the period of time required for production included in the actual performance information, and the work time included in the planning master, and change the planning parameter based on how greatly the work time included in the planning master is changed.

4. A production planning apparatus according to claim 1,

wherein the storage unit includes master change influence information including a basis on which information included in the planning parameter is to be changed based on an increase or decrease of the information included in the planning master, and

wherein the parameter generation processing unit is further configured to change the planning parameter in accordance with the master change influence information.

5. A production planning apparatus according to claim 1,

wherein the parameter generation processing unit is further configured to increase the safety stock quantity of the item based on a decreased amount of the percent defective of the item.

6. A production planning apparatus according to claim 1, wherein the production plan processing unit is further configured to identify a combination of the planning master and the planning parameter that maximizes an on-time delivery rate and productivity through a combinatorial optimization procedure.

7. A production planning apparatus according to claim 1, wherein the production plan processing unit is further configured to receive a threshold value of an on-time delivery rate in the calculation of the production plan, and identify a combination of the planning master and the planning parameter that allows the on-time delivery rate to exceed the threshold value.

8. A production planning apparatus according to claim 1,

wherein the safety stock of the item is set in preparation for deterioration of the percent defective of the item until the percent defective becomes stable, such that when a period in which the percent defective of the item becomes stable is observed, a stock quantity of the item is adjusted so as to minimize the safety stock quantity of the item to be held after the period.

9. A production planning apparatus, comprising:

a parameter generation processing unit configured to;

receive, from an external apparatus, actual performance information on a resource required for production and a planning master including a plan of a resource required for work of the production, the plan of the resource including a percent defective of an item specifying a product or a part of the product to be produced under the production;

change the plan of the resource required for the work including the percent defective of the item, which is included in the planning master, based on a difference between the plan of the resource, which is included in the planning master, and actual performance of the resource required for the production, which is included in the actual performance information; and

calculate a planning parameter including a variable required for a production plan based on how greatly the planning master is changed, the planning parameter including information specifying a safety stock which is information specifying a safety stock quantity of the item, the safety stock being set in preparation for deterioration of the percent defective of the item; and

an output unit configured to transmit the planning master and the planning parameter to the external apparatus.

10. A production planning apparatus according to claim 9,

wherein the actual performance information includes information specifying an input quantity for production and a completed quantity,

wherein the percent defective included in the planning master is a planned percent defective, and

wherein the parameter generation processing unit is further configured to use the input quantity for production and the completed quantity, which are included in the actual performance information, to calculate an actual value of a percent defective of the item, change the planned percent defective of the item included in the planning master based on a difference between the actual value and the planned percent defective included in the planning master, and change the information specifying the safety stock based on how greatly the planned percent defective included in the planning master is changed.

11. A production planning apparatus according to claim 9,

wherein the actual performance information includes information specifying a production quantity and a period of time required for production,

wherein the planning master includes a work time, and

wherein the parameter generation processing unit is further configured to change the work time included in the planning master based on a difference between an actual value of the work time, which is calculated based on the production quantity and the period of time required for production included in the actual performance information, and the work time included in the planning master, and change the planning parameter based on how greatly the work time included in the planning master is changed.

12. A production planning apparatus according to claim 9,

wherein the parameter generation processing unit is further configured to receive, from the external apparatus, master change influence information including a basis on which information included in the planning parameter is to be changed based on an increase or decrease of the information included in the planning master, and

wherein the parameter generation processing unit is further configured to change the planning parameter in accordance with the master change influence information.

13. A production planning apparatus according to claim 9,

wherein the parameter generation processing unit is further configured to increase the safety stock quantity of the item based on a decreased amount of the percent defective of the item.

14. A production planning apparatus according to claim 9,

wherein the safety stock of the item is set in preparation for deterioration of the percent defective of the item until the percent defective becomes stable, such that when a period in which the percent defective of the item becomes stable is observed, a stock quantity of the item is adjusted so as to minimize the safety stock quantity of the item to be held after the period.

15. A production planning method for causing a computer to execute a procedure for planning production,

the computer comprising:

a storage unit configured to store;

actual performance information on a resource required for production;

a planning master including a plan of a resource required for work of the production, the plan of the resource including a percent defective of an item specifying a product or a part of the product to be produced under the production; and

a planning parameter including a variable required for a production plan, the planning parameter including information specifying a safety stock which is information specifying a safety stock quantity of the item, the safety stock being set in preparation for deterioration of the percent defective of the item; and

a control unit,

the production planning method comprising executing, by the control unit;

a parameter generation processing step of changing the plan of the resource required for the work including the percent defective of the item, which is included in the planning master, based on a difference between the plan of the resource, which is included in the planning master, and actual performance of the resource required for the production, which is included in the actual performance information, and changing the planning parameter including the information specifying the safety stock based on how greatly the planning master is changed; and

a production plan processing step of calculating a production plan that uses the planning master and the planning parameter.

16. A production planning method according to claim 15,

wherein the actual performance information includes information specifying an input quantity for production and a completed quantity,

wherein the percent defective included in the planning master is a planned percent defective, and

wherein the parameter generation processing step further includes using the input quantity for production and the completed quantity, which are included in the actual performance information, to calculate an actual value of a percent defective of the item, changing the planned percent defective of the item included in the planning master based on a difference between the actual value and the planned percent defective included in the planning master, and changing the information specifying the safety stock based on how greatly the planned percent defective included in the planning master is changed.

17. A production planning method according to claim 15,

wherein the actual performance information includes information specifying a production quantity and a period of time required for production,

wherein the planning master includes a work time, and

wherein the parameter generation processing step further includes changing the work time included in the planning master based on a difference between an actual value of the work time, which is calculated based on the production quantity and the period of time required for production included in the actual performance information, and the work time included in the planning master, and changing the planning parameter based on how greatly the work time included in the planning master is changed.

18. A production planning method according to claim 15,

wherein the parameter generation processing step further includes receiving, from the external apparatus, master change influence information including a basis on which information included in the planning parameter is to be changed based on an increase or decrease of the information included in the planning master, and changing the planning parameter in accordance with the master change influence information.

19. A production planning method according to claim 15,

wherein the parameter generation processing step further includes increasing the safety stock quantity of the item based on a decreased amount of the percent defective of the item.

20. A production planning method according to claim 15,

wherein the safety stock of the item is set in preparation for deterioration of the percent defective of the item until the percent defective becomes stable, such that when a period in which the percent defective of the item becomes stable is observed, a stock quantity of the item is adjusted so as to minimize the safety stock quantity of the item to be held after the period.