Method for purchase order rescheduling in a linear program

• US 7,966,208 B2
• Filed: 01/29/2004
• Issued: 06/21/2011
• Est. Priority Date: 01/29/2004
• Status: Expired due to Fees

• Current Assignee: International Business Machines Corporation
• Original Assignee: International Business Machines Corporation
• Inventors: Orzell, Robert A., Milne, Robert J., Denton, Brian T.
• Primary Examiner(s): Sterrett; Jonathan G.
• Assistant Examiner(s): KARDOS, NEIL R
• Application Number:
  US10/707,974
• Publication Number:
  US 20050171825A1
• Time in Patent Office: 2,700 Days
• Field of Search: 705/8
• US Class Current: 705/7.12
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/0631 Resource planning, allocation, distributing or scheduling for enterprises or organisations
• CPC Class Codes: G06Q 10/06312 Adjustment or analysis of established resource schedule, e.g. resource or task levelling, or dynamic rescheduling
• CPC Class Codes: G06Q 10/06314 Calendaring for a resource
• CPC Class Codes: G06Q 10/06315 Needs-based resource requirements planning or analysis
• CPC Class Codes: G06Q 30/06 Buying, selling or leasing transactions

Abstract

The invention provides a method of rescheduling timing of when items on purchase orders are scheduled to be received in a linear programming production planning system. This methodology performs a pre-processing rescheduling of the timing of purchase order receipts into the earliest time period allowable in a pre-processing step. After this pre-processing, the invention solves the core production planning system equations using the rescheduled purchase order receipts. Then, the invention performs post-processing rescheduling, which sorts the purchase order receipts according to rescheduling flexibility, and subsequently sequentially reschedules the timing of each of the purchase order receipts in the order established by the sorting process. This process of sequentially rescheduling reschedules the timing of purchase order receipts into the latest time period allowable.

Claims

1. A computer-implemented method for determining a production plan, said method comprising:

receiving, by a computer, a file comprising purchase order receipts, said purchase order receipts being defined as line items on purchase orders;

performing, by said computer, a first rescheduling process, said first rescheduling process comprising;

evaluating each purchase order receipt to determine whether rescheduling of said purchase order receipt is one of permissible and impermissible, as indicated by a flag; and

for all of said purchase order receipts for which rescheduling is determined to be permissible, rescheduling when said purchase order receipts are to be received by a plant so as to indicate that said purchase order receipts will be received by said plant during earlier time periods than initially specified;

after said performing of said first rescheduling process, solving core production planning system equations with linear programming using rescheduled purchase order receipts associated with said earlier time periods from said first rescheduling process so as to determine an initial production plan;

after said solving of said core production planning system equations with said linear programming, performing, by said computer, post-processing, said post-processing comprising;

performing a second rescheduling process, said second rescheduling process comprising rescheduling when said rescheduled purchase order receipts from said first rescheduling process are to be received by said plant so as to indicate that said rescheduled purchase order receipts will be received by said plant during later time periods than specified during said first rescheduling process without causing inventory balances to be depleted to zero; and

generating and outputting, by said computer, a final production plan based on said initial production plan and said second rescheduling process.

2. The method of claim 1, said flag comprising a net up front flag indicating that said purchase order receipt may not be rescheduled to an earlier point in time.

3. The method of claim 1, said flag comprising a frozen in zone flag specifying a time period within which said purchase order receipt can be rescheduled.

4. The method of claim 1, said second rescheduling process being based upon one of a date of need, frozen zone rules, and date tolerances.

5. The method of claim 1, further comprising after said solving, sorting of said rescheduled purchase order receipts from said first rescheduling process.

6. The method of claim 5, said sorting being based upon one of arrival dates, purchase order receipt quantity, and the flexibility of purchase order receipt movement with respect to frozen zone rules.

7. The method of claim 1, further comprising recomputing ending inventory levels to reflect said second rescheduling process.

8. A computer-implemented method of rescheduling timing of when items on purchase orders are rescheduled to be received in a linear programming production planning system, said method comprising:

receiving, by a computer, a file comprising purchase order receipts, said purchase order receipts being defined as line items on purchase orders;

performing, by said computer, a first rescheduling process, said first rescheduling process comprising;

evaluating each purchase order receipt to determine whether rescheduling of said purchase order receipt is one of permissible and impermissible, as indicated by a flag comprising any one of a net up front flag indicating that said purchase order receipt may not be rescheduled to an earlier point in time and a frozen in zone flag specifying a time period within which said purchase order receipt can be rescheduled; and

for all of said purchase order receipts for which rescheduling is determined to be permissible, rescheduling when said purchase order receipts are to be received by a plant so as to indicate that said purchase order receipts will be received by said plant during the earliest time periods allowable by a supplier;

after said performing of said first rescheduling process, solving core production planning system equations with linear programming using rescheduled purchase order receipts associated with said earliest time periods allowable by said supplier from said first rescheduling process so as to determine an initial production plan;

after said solving of said core production planning system equations with said linear programming, performing, by said computer, post-processing, said post-processing comprising;

sorting said rescheduled purchase order receipts from said first rescheduling process, based on predetermined criteria;

based on said sorting, performing, by said computer, a second rescheduling process, said second rescheduling process comprising rescheduling when said rescheduled purchase order receipts from said first rescheduling process are to be received by said plant so as to indicate that said rescheduled purchase order receipts will be received by said plant during the latest time periods allowable by said supplier without causing inventory balances to be depleted to zero; and

generating and outputting, by said computer, a final production plan based on said initial production plan and said second rescheduling process.

9. The method in claim 8, said sorting comprising:

sorting said rescheduled purchase order receipts into different classes of rescheduling flexibility;

sorting said rescheduled purchase order receipts within each of said classes of rescheduling flexibility into different classes of arrival dates; and

sorting said rescheduled purchase order receipts within each of said classes of arrival dates based on quantities within said rescheduled purchase order receipts.

10. The method in claim 8, said second rescheduling process rescheduling each of said purchase order receipts into the latest time period before the corresponding inventory level would be depleted to zero.

11. The method in claim 8, said first rescheduling process further comprising, for each purchase order receipt, determining whether a time period for receiving by said plant of said purchase order receipt can be extended beyond the latest date of the planning horizon of said linear programming production planning system;

and, if so, eliminating said purchase order receipt.

12. The method in claim 8, further comprising recomputing ending inventory levels to reflect said second rescheduling process.

13. The method in claim 8, said second rescheduling process further limiting rescheduling to comply with contractual obligations and to avoid trivial rescheduling.

14. A computer-implemented method of rescheduling timing of when items on purchase orders are rescheduled to be received in a linear programming production planning system, said method comprising:

receiving, by a computer, a file comprising purchase order receipts, said purchase order receipts being defined as line items on purchase orders;

performing, by said computer, a first rescheduling process, said first rescheduling process comprising;

evaluating each purchase order receipt to determine whether rescheduling of said purchase order receipt is one of permissible and impermissible, as indicated by a first flag comprising any one of a net up front flag indicating that said purchase order receipt may not be rescheduled to an earlier point in time and a frozen in zone flag specifying a time period within which said purchase order receipt can be rescheduled; and

for all of said purchase order receipts for which rescheduling is determined to be permissible, rescheduling when said purchase order receipts are to be received by a plant so as to indicate that said purchase order receipts will be received by said plant during the earliest time periods allowable by a supplier;

after said performing of said first rescheduling process, solving core production planning system equations with linear programming using rescheduled purchase order receipts associated with said earliest time periods allowable by said supplier from said first rescheduling process so as to determine an initial production plan;

after said solving of said core production planning system equations with said linear programming, performing, by said computer, post-processing, said post-processing comprising;

sorting said rescheduled purchase order receipts from said first rescheduling process according to rescheduling flexibility, said sorting comprising, for each rescheduled purchase order receipt, determining whether rescheduling is still permissible, as indicated by a second flag, said second flag comprising a frozen out zone flag specifying another time period within which said rescheduled purchase order receipt can not be rescheduled later in time;

based on said sorting, performing, by said computer, a second rescheduling process, said second rescheduling process comprising, for all of said rescheduled purchase order receipts for which rescheduling is determined to be still permissible, rescheduling when said rescheduled purchase order receipts from said first rescheduling process are to be received by said plant so as to indicate that said rescheduled purchase order receipts will be received by said plant during the latest time periods allowable by said supplier without causing inventory balances to be depleted to zero; and

generating and outputting, by said computer, a final production plan based on said initial production plan and said second rescheduling process.

15. The method in claim 14, said sorting comprising:

sorting said rescheduled purchase order receipts into different classes of rescheduling flexibility;

sorting said rescheduled purchase order receipts within each of said classes of rescheduling flexibility into different classes of arrival dates; and

sorting said rescheduled purchase order receipts within each of said classes of arrival dates based on quantities within said rescheduled purchase order receipts.

16. The method in claim 14, said second rescheduling process rescheduling each of said rescheduled purchase order receipts into the latest time period before the corresponding inventory level would be depleted to zero.

17. The method in claim 14, said first rescheduling process further comprising, for each purchase order receipt, determining whether a time period for receiving by said plant of said purchase order receipt can be extended beyond the latest date of the planning horizon of said linear programming production planning system;

and, if so, eliminating said purchase order receipt.

18. The method in claim 14, further comprising recomputing ending inventory levels to reflect said second rescheduling process.

19. A program storage device readable by machine, tangibly embodying a program of instructions executable by the machine to perform a method of rescheduling timing of when items on purchase orders are rescheduled to be received in a linear programming production planning system, said method comprising:

receiving a file comprising planned purchase order receipts, said purchase order receipts being defined as line items on purchase orders;

performing a first rescheduling process, said first rescheduling process comprising;

evaluating each purchase order receipt to determine whether rescheduling of said purchase order receipt is one of permissible and impermissible, as indicated by a flag comprising any one of a net up front flag indicating that said purchase order receipt may not be rescheduled to an earlier point in time and a frozen in zone flag specifying a time period within which said purchase order receipt can be rescheduled; and

for all of said purchase order receipts for which rescheduling is determined to be permissible, rescheduling when said purchase order receipts are to be received by a plant so as to indicate that said purchase order receipts will be received by said plant during the earliest time periods allowable by a supplier;

after said performing of said first rescheduling process, solving core production planning system equations with linear programming using rescheduled purchase order receipts associated with said earliest time periods allowable by said supplier from said first rescheduling process so as to determine an initial production plan;

after said solving of said core production planning system equations with said linear programming, performing, by said computer, post-processing, said post-processing comprising;

sorting said rescheduled purchase order receipts from said first rescheduling process, based on predetermined criteria;

based on said sorting, performing a second rescheduling process, said second rescheduling process comprising rescheduling when said rescheduled purchase order receipts from said first rescheduling process are to be received by said plant so as to indicate that said rescheduled purchase order receipts are to be received by said plant during the latest time periods allowable by said supplier without causing inventory balances to be depleted to zero; and

generating and outputting a final production plan based on said initial production plan and said second rescheduling process.

20. The program storage device in claim 19, said sorting comprising:

sorting said rescheduled purchase order receipts into different classes of rescheduling flexibility;

sorting said rescheduled purchase order receipts within each of said classes of rescheduling flexibility into different classes of arrival dates; and

sorting said rescheduled purchase order receipts within each of said classes of arrival dates based on quantities within said rescheduled purchase order receipts.

21. The program storage device in claim 19, said second rescheduling process rescheduling each of said rescheduled purchase order receipts into the latest time period before the corresponding inventory level would be depleted to zero.

22. The program storage device in claim 19, said first rescheduling process further comprising, for each purchase order receipt, determining whether a time period for receiving by said plant of said purchase order receipt can be extended beyond the latest date of the planning horizon of said linear programming production planning system;

and, if so, eliminating said purchase order receipt.

23. The program storage device in claim 19, said method further comprising recomputing ending inventory levels to reflect said second rescheduling process.

24. The program storage device in claim 19, said second rescheduling process further limiting rescheduling to comply with contractual obligations and to avoid trivial rescheduling.