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WO2021090392A1 - Système de calcul de coût d'inventaire, procédé de calcul de coût d'inventaire et programme de calcul de coût d'inventaire - Google Patents

Système de calcul de coût d'inventaire, procédé de calcul de coût d'inventaire et programme de calcul de coût d'inventaire Download PDF

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Publication number
WO2021090392A1
WO2021090392A1 PCT/JP2019/043444 JP2019043444W WO2021090392A1 WO 2021090392 A1 WO2021090392 A1 WO 2021090392A1 JP 2019043444 W JP2019043444 W JP 2019043444W WO 2021090392 A1 WO2021090392 A1 WO 2021090392A1
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WIPO (PCT)
Prior art keywords
inventory
stage
manufacturing process
unit
cost calculation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2019/043444
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English (en)
Japanese (ja)
Inventor
彩 小牟▲禮▼
隆臣 佐藤
剛大 石黒
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mitsubishi Electric Corp
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Mitsubishi Electric Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mitsubishi Electric Corp filed Critical Mitsubishi Electric Corp
Priority to PCT/JP2019/043444 priority Critical patent/WO2021090392A1/fr
Priority to JP2020528352A priority patent/JP6779417B1/ja
Priority to CN201980101943.4A priority patent/CN114630799A/zh
Priority to TW109106212A priority patent/TW202119151A/zh
Publication of WO2021090392A1 publication Critical patent/WO2021090392A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G61/00—Use of pick-up or transfer devices or of manipulators for stacking or de-stacking articles not otherwise provided for
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/04—Manufacturing

Definitions

  • the present invention relates to a method for calculating costs incurred inside and outside a factory in the manufacturing industry.
  • the conventional inventory cost calculation method only calculates the cost of the entire inventory and does not calculate the inventory cost per piece or production lot, so that the inventory cost cannot be calculated with high accuracy.
  • An object of the present invention is to calculate an inventory cost per piece or production lot.
  • the inventory cost calculation system of the present invention The place where the inventory in the stage before processing due to the manufacturing process flow including multiple manufacturing processes stays, the place where the inventory in the stage during processing in each manufacturing process stays, and the stage waiting for processing between each manufacturing process.
  • the retention time of each inventory at each stage is measured by using the inventory detection sensors installed at the location where the inventory stays and the location where the inventory at the stage after processing according to the manufacturing process flow stays.
  • With the residence time measurement unit It is provided with an inventory cost calculation unit that calculates the inventory cost required for each inventory at each stage based on the residence time of each inventory at each stage.
  • the inventory cost at each stage can be calculated for each inventory. Therefore, it is possible to properly derive a plan such as a production plan or a transportation plan.
  • FIG. The block diagram of the manufacturing process data 294 in Embodiment 1.
  • the flowchart of the inventory cost calculation process (S130) in Embodiment 1. The figure which shows an example of the inventory cost graph 111 in Embodiment 1.
  • FIG. The figure which shows an example of the manufacturing process flow in Embodiment 1.
  • FIG. The figure which shows an example of the manufacturing process in Embodiment 1.
  • FIG. The block diagram of the inventory cost calculation system 100 in Embodiment 2.
  • FIG. The block diagram of the total cost calculation apparatus 300 in Embodiment 2.
  • FIG. The block diagram of the storage part 390 in Embodiment 2.
  • FIG. The block diagram of the product type data 391 in Embodiment 2.
  • FIG. The block diagram of the completed inventory group data 392 in Embodiment 2.
  • FIG. The block diagram of the total cost data 393 in Embodiment 2.
  • FIG. The flowchart of the total cost calculation method in Embodiment 2.
  • FIG. The figure which shows an example of the manufacturing process flow in Embodiment 2.
  • FIG. The figure which shows another example of the product type data 391 in Embodiment 2.
  • FIG. The figure which shows another example of the material data 394 in Embodiment 2.
  • FIG. The hardware configuration diagram of the inventory cost calculation device 200 in the embodiment.
  • Embodiment 1 The inventory cost calculation system 100 will be described with reference to FIGS. 1 to 15.
  • the configuration of the inventory cost calculation system 100 is a system for calculating the inventory cost of each inventory at each stage of the manufacturing process flow.
  • the manufacturing process flow is a procedure for processing a material to produce a product (finished product), and includes a plurality of manufacturing processes.
  • the stage before processing according to the manufacturing process flow is called the "material stage”.
  • the stage during processing in the manufacturing process is referred to as “processing stage”.
  • the stage of waiting for processing between manufacturing processes is called “inter-process stage”.
  • the post-processing stage according to the manufacturing process flow is called the "completion stage”.
  • the inventory cost calculation system 100 includes a plurality of inventory detection sensors 101, an inventory cost calculation device 200, and a display 102.
  • the plurality of inventory detection sensors 101 and the inventory cost calculation device 200 communicate with each other via a network.
  • the display 102 is connected to the inventory cost calculation device 200.
  • Each of the plurality of inventory detection sensors 101 is installed at a different location from each other. Each inventory detection sensor 101 is installed at a place where material inventory stays, a place where inventory during processing stays, a place where interprocess inventory stays, or a place where finished inventory stays.
  • the material inventory is the inventory at the stage (material stage) before processing according to the manufacturing process flow, that is, the inventory that becomes the material of the product.
  • the in-processing inventory is an inventory in the process of processing (in-process stage) in the manufacturing process, that is, an inventory in a state of being processed.
  • the inter-process inventory is an inventory at a stage waiting for processing (inter-process stage) between manufacturing processes, that is, an inventory waiting for processing.
  • the conventional work-in-process inventory is a combination of in-process inventory and inter-process inventory.
  • the finished inventory is the inventory at the post-processing stage (completion stage) according to the manufacturing process flow, that is, the inventory of the finished product (product).
  • Each inventory detection sensor 101 is a sensor for detecting each inventory remaining in the installation location. Each inventory is detected as follows. An inventory identifier is attached to each inventory. The method of attaching the inventory identifier is arbitrary. For example, the inventory identifier may be written on the surface of the inventory, the code representing the inventory identifier may be written on the surface of the inventory, or the IC tag on which the inventory identifier is recorded may be mounted on the inventory. Bar codes and QR codes (registered trademarks) are examples of codes. IC is an abbreviation for integrated circuit. Each inventory detection sensor 101 detects each inventory by reading the inventory identifier attached to each inventory. The method of reading the inventory identifier is arbitrary. For example, the inventory detection sensor 101 is an image sensor.
  • the image sensor obtains an image showing the accumulated inventory by taking a picture. Then, the image sensor detects the inventory identifier attached to the inventory by image processing.
  • the inventory detection sensor 101 is a code reader. The code reader reads the inventory identifier from the code written on the inventory.
  • the inventory detection sensor 101 is a reader / writer. The reader / writer reads the inventory identifier from the IC tag by wireless communication with the IC tag mounted on the inventory.
  • Inventory is a unit quantity.
  • a specific example of the unit quantity is one piece or one lot. It is possible to assign an inventory identifier to each piece, including small parts such as small screws, which can be handled as a unit quantity.
  • the inventory identifier identifies the inventory.
  • the inventory cost calculation device 200 uses a plurality of inventory detection sensors 101 to measure the residence time of each inventory at each stage. Then, the inventory cost calculation device 200 calculates the cost (inventory cost) required for each inventory at each stage based on the residence time of each inventory at each stage. Further, the inventory cost calculation device 200 displays a graph showing the inventory cost of each stage for each inventory on the display 102.
  • the configuration of the inventory cost calculation device 200 is a computer including hardware such as a processor 201, a memory 202, an auxiliary storage device 203, a communication device 204, and an input / output interface 205. These hardware are connected to each other via signal lines.
  • the processor 201 is an IC that performs arithmetic processing and controls other hardware.
  • processor 201 is a CPU, DSP or GPU.
  • IC is an abbreviation for Integrated Circuit.
  • CPU is an abbreviation for Central Processing Unit.
  • DSP is an abbreviation for Digital Signal Processor.
  • GPU is an abbreviation for Graphics Processing Unit.
  • the memory 202 is a volatile or non-volatile storage device.
  • the memory 202 is also referred to as a main storage device or a main memory.
  • the memory 202 is a RAM.
  • the data stored in the memory 202 is stored in the auxiliary storage device 203 as needed.
  • RAM is an abbreviation for Random Access Memory.
  • the auxiliary storage device 203 is a non-volatile storage device.
  • the auxiliary storage device 203 is a ROM, HDD, or flash memory.
  • the data stored in the auxiliary storage device 203 is loaded into the memory 202 as needed.
  • ROM is an abbreviation for Read Only Memory.
  • HDD is an abbreviation for Hard Disk Drive.
  • Communication device 204 is a receiver and a transmitter.
  • the communication device 204 is a communication chip or NIC.
  • NIC is an abbreviation for Network Interface Card.
  • the input / output interface 205 is a port to which an input device and an output device are connected.
  • the input / output interface 205 is a USB terminal
  • the input device is a keyboard and a mouse
  • the output device is a display 102.
  • USB is an abbreviation for Universal Serial Bus.
  • the inventory cost calculation device 200 includes elements such as a general-purpose data reception unit 210, a residence time measurement unit 220, an inventory cost calculation unit 230, and an inventory cost display unit 240. These elements are realized in software.
  • the auxiliary storage device 203 stores an inventory cost calculation program for operating a computer as a general-purpose data reception unit 210, a residence time measurement unit 220, an inventory cost calculation unit 230, and an inventory cost display unit 240.
  • the inventory cost calculation program is loaded into the memory 202 and executed by the processor 201.
  • the OS is further stored in the auxiliary storage device 203. At least part of the OS is loaded into memory 202 and executed by processor 201.
  • the processor 201 executes the inventory cost calculation program while executing the OS.
  • OS is an abbreviation for Operating System.
  • the input / output data of the inventory cost calculation program is stored in the storage unit 290.
  • the memory 202 functions as a storage unit 290.
  • a storage device such as an auxiliary storage device 203, a register in the processor 201, and a cache memory in the processor 201 may function as a storage unit 290 instead of the memory 202 or together with the memory 202.
  • the inventory cost calculation device 200 may include a plurality of processors that replace the processor 201.
  • the plurality of processors share the functions of the processor 201.
  • the inventory cost calculation program can record (store) in a non-volatile recording medium such as an optical disk or a flash memory so that it can be read by a computer.
  • the configuration of the storage unit 290 will be described with reference to FIG.
  • the storage unit 290 stores consumption data 291, unit price data 292, sensor management data 293, manufacturing process data 294, residence time data 295, inventory cost data 296, and the like.
  • the consumption data 291 will be described with reference to FIG.
  • the consumption data 291 shows the consumption of each resource per unit time at each stage.
  • resources are materials, energy and workers.
  • the resources generated during the machining stage are the electric power energy that moves the machine when the process is a manual work, and the worker when the process is a manual work.
  • the resources generated in the inter-process stage are electric power energy for maintaining the space in which the inventory exists in an appropriate state, and a worker who manages the inventory existing in the inter-process.
  • the consumption amount data 291 is a table in which the inventory category identifier, the stage identifier, the resource identifier, and the consumption amount are associated with each other.
  • the inventory category identifier is an identifier that represents an inventory category.
  • the inventory category identifier is the model number of the inventory.
  • a plurality of inventory identifiers exist based on one inventory category identifier.
  • the unit price data 292 will be described with reference to FIG.
  • the unit price data 292 indicates the unit price of each resource. That is, the unit price data 292 indicates the price of each resource per unit.
  • the unit price data 292 is a table in which the resource identifier, the time proportion, and the unit price are associated with each other. The pair of the resource identifier, the time proportionality, and the unit price is referred to as a "unit price record".
  • the sensor management data 293 will be described with reference to FIG.
  • the sensor management data 293 indicates a stage corresponding to each inventory detection sensor 101. That is, the sensor management data 293 is a stage corresponding to a place where inventory is detected by each inventory detection sensor 101.
  • the sensor management data 293 is a table in which a sensor identifier and a stage identifier are associated with each other. The set of the sensor identifier and the stage identifier is referred to as a "sensor management record".
  • the manufacturing process data 294 will be described with reference to FIG. 7.
  • the manufacturing process data 294 shows the manufacturing process of each detected inventory.
  • the manufacturing process is the process at which inventory has passed.
  • the manufacturing process data 294 is a table in which the inventory identifier, the manufacturing process information, and the inventory cost are associated with each other.
  • the manufacturing process information is information indicating the manufacturing process of inventory, and is represented by one or more stage identifiers arranged in order.
  • Inventory cost indicates the cost required for inventory in the manufacturing process.
  • the set of the inventory identifier, the manufacturing process information, and the inventory cost is called a "manufacturing process record".
  • the residence time data 295 will be described with reference to FIG.
  • the dwell time data 295 shows the dwell time of each inventory at each stage.
  • the residence time data 295 is a table in which an inventory identifier, a stage identifier, a resource identifier, a start time, an end time, and a residence time are associated with each other.
  • a set of an inventory identifier, a stage identifier, a resource identifier, a start time, an end time, and a residence time is called a "retention time record".
  • Inventory cost data 296 will be described with reference to FIG. Inventory cost data 296 shows the inventory cost of each stage for each inventory. Specifically, the inventory cost data 296 is a table in which an inventory identifier, a stage identifier, and an inventory cost are associated with each other. Inventory cost indicates the cost required for inventory at each stage. A set of an inventory identifier, a stage identifier, and an inventory cost is called an "inventory cost record".
  • the operation procedure of the inventory cost calculation system 100 corresponds to the inventory cost calculation method. Further, the operation procedure of the inventory cost calculation system 100 (particularly, the inventory cost calculation device 200) corresponds to the processing procedure by the inventory cost calculation program.
  • step S110 the user inputs the consumption amount data 291 and the unit price data 292 and the sensor management data 293 into the inventory cost calculation device 200.
  • the general-purpose data receiving unit 210 receives consumption data 291 and unit price data 292 and sensor management data 293. Then, the general-purpose data receiving unit 210 stores the consumption amount data 291 and the unit price data 292 and the sensor management data 293 in the storage unit 290.
  • step S120 the residence time measuring unit 220 measures the residence time of each inventory at each stage by using each inventory detection sensor 101.
  • the residence time of each inventory at each stage is measured as follows. First, the residence time measurement unit 220 uses each inventory detection sensor 101 to detect the stage at which each inventory is retained at each time. The stage in which each inventory is retained is referred to as a "retention stage”. Then, the residence time measurement unit 220 calculates the residence time of each inventory at each stage based on the retention stage of each inventory at each time.
  • step S130 the inventory cost calculation unit 230 calculates the cost required for each inventory at each stage based on the residence time of each inventory at each stage.
  • the calculated cost is referred to as "inventory cost”.
  • the inventory cost calculation unit 230 calculates the inventory cost at each stage for each stock by using the residence time data 295, the consumption data 291 and the unit price data 292.
  • step S140 the inventory cost display unit 240 displays a graph showing the inventory cost of each stage for each inventory.
  • the details of the inventory cost display processing (S140) will be described later.
  • Steps S121 to S124 are executed every time each inventory detection data is output from each inventory detection sensor 101.
  • Each inventory detection sensor 101 detects each inventory remaining in the installation location at each time. Then, the inventory detection sensor 101 outputs inventory detection data indicating each detected inventory at each time.
  • the inventory detection data includes a sensor identifier, an inventory identifier, and a detection time.
  • the sensor identifier in the inventory detection data identifies the inventory detection sensor 101 that outputs the inventory detection data.
  • the inventory identifier in the inventory detection data identifies the detected inventory.
  • the detection time in the inventory detection data is the time when the inventory is detected.
  • step S121 the residence time measuring unit 220 receives each inventory detection data from each inventory detection sensor 101.
  • the residence time measuring unit 220 extracts the stage identifier corresponding to the received inventory detection data from the sensor management data 293.
  • the sensor identifier and the stage identifier have the same value.
  • the plurality of sensor identifiers are the extraction sources of the stage identifiers.
  • the residence time measurement unit 220 extracts from the sensor management data 293 a step identifier associated with the same sensor identifier as the sensor identifier in the inventory detection data.
  • the stage identified by the extracted stage identifier is the retention stage.
  • step S123 the residence time measurement unit 220 updates the manufacturing process information in the manufacturing process record corresponding to the received inventory detection data.
  • the residence time measuring unit 220 operates as follows. First, the residence time measurement unit 220 selects a manufacturing process record including the same inventory identifier as the inventory identifier in the received inventory detection data from the manufacturing process data 294. Then, the residence time measuring unit 220 adds the step identifier extracted in step S122 to the manufacturing process information in the selected manufacturing process record. However, if the extracted stage identifier is included in the manufacturing process information in the selected manufacturing process record, it is not necessary to add the extracted stage identifier.
  • the residence time measuring unit 220 When the manufacturing process record corresponding to the received inventory detection data does not exist, the residence time measuring unit 220 generates the manufacturing process record and registers the generated manufacturing process record in the manufacturing process data 294.
  • the inventory identifier in the registered manufacturing process record is the same as the inventory identifier in the received inventory detection data.
  • the manufacturing process information in the registered manufacturing process record indicates the stage identifier extracted in step S122.
  • the inventory cost of the registered manufacturing process record is zero.
  • step S124 the residence time measurement unit 220 updates the residence time record corresponding to the received inventory detection data.
  • the dwell time record to be updated includes the same inventory identifier as the inventory identifier in the received inventory detection data and the same stage identifier as the stage identifier extracted in step S122.
  • the residence time measuring unit 220 operates as follows. First, the residence time measurement unit 220 selects a residence time record corresponding to the received inventory detection data from the residence time data 295. Then, the residence time measurement unit 220 updates the selected residence time record as follows. The residence time measurement unit 220 updates the end time in the selected residence time record to the detection time in the inventory detection data. The residence time measurement unit 220 updates the residence time in the selected residence time record to the length of time from the start time in the selected residence time record to the detection time in the inventory detection data.
  • the residence time measurement unit 220 When there is no residence time record corresponding to the received inventory detection data, the residence time measurement unit 220 generates a residence time record and registers the generated residence time record in the residence time data 295.
  • the inventory identifier in the registered residence time record is the same as the inventory identifier in the received inventory detection data.
  • the stage identifier in the registered residence time record is the same as the stage identifier extracted in step S122.
  • the start time in the registered residence time record is the same as the detection time in the received inventory detection data.
  • the end time in the registered residence time record is the same as the detection time in the received inventory detection data.
  • the dwell time in the registered dwell time record is zero.
  • step S131 the inventory cost calculation unit 230 extracts the consumption amount record group corresponding to the residence time record updated in step S124 (see FIG. 11) from the consumption amount data 291.
  • a consumption record group is one or more consumption records.
  • the inventory cost calculation unit 230 extracts one or more consumption records including the same stage identifier as the stage identifier in the updated residence time record from the consumption data 291.
  • step S132 the inventory cost calculation unit 230 selects one unselected consumption record from the extracted consumption record group.
  • step S133 the inventory cost calculation unit 230 extracts the unit price record corresponding to the selected consumption amount record from the unit price data 292. Specifically, the inventory cost calculation unit 230 extracts a unit price record including the same resource identifier as the resource identifier in the selected consumption record from the unit price data 292.
  • the inventory cost calculation unit 230 calculates the cost for each resource by using the updated residence time record, the selected consumption amount record, and the extracted unit price record. Specifically, when the time proportionality of the unit price record is applicable, the inventory cost calculation unit 230 extracts the residence time from the updated residence time record, extracts the consumption amount from the selected consumption amount record, and extracts it. Extract the unit price from the unit price record. Then, the inventory cost calculation unit 230 multiplies the extracted unit price by the extracted consumption amount and the extracted residence time. The cost calculated by this is the cost by resource. On the other hand, when the time proportionality of the unit price record is not applicable, the inventory cost calculation unit 230 extracts the consumption amount from the selected consumption amount record and extracts the unit price from the extracted unit price record. Then, the inventory cost calculation unit 230 multiplies the extracted unit price by the extracted consumption amount. The cost calculated by this is the cost by resource.
  • step S135 the inventory cost calculation unit 230 determines whether or not there is an unselected consumption record in the extracted consumption record group. If there is an unselected consumption record, the process proceeds to step S132. If there is no unselected consumption record, the process proceeds to step S136.
  • step S136 the inventory cost calculation unit 230 calculates the total of the calculated resource-specific costs.
  • the calculated total is referred to as the "step cost”.
  • step S137 the inventory cost calculation unit 230 updates the inventory cost in the inventory cost record corresponding to the updated residence time record.
  • the inventory cost calculation unit 230 operates as follows. First, the inventory cost calculation unit 230 generates an inventory cost record including the same inventory identifier as the inventory identifier in the updated residence time record and the same stage identifier as the stage identifier in the updated residence time record. Select from inventory cost data 296. Then, the inventory cost calculation unit 230 updates the inventory cost in the selected inventory cost record to the step cost calculated in step S136.
  • the inventory cost calculation unit 230 When the inventory cost record corresponding to the updated dwell time record does not exist, the inventory cost calculation unit 230 generates the inventory cost record and registers the generated inventory cost record in the inventory cost data 296.
  • the inventory identifier in the inventory cost record to be created is the same as the inventory identifier in the updated dwell time record.
  • the stage identifier in the inventory cost record to be created is the same as the stage identifier in the updated dwell time record.
  • the inventory cost in the inventory cost record to be registered is the same as the step cost calculated in step S136.
  • step S138 the inventory cost calculation unit 230 updates the inventory cost in the manufacturing process record corresponding to the updated residence time record.
  • the inventory cost calculation unit 230 operates as follows. First, the inventory cost calculation unit 230 extracts the inventory cost record group corresponding to the updated residence time record from the inventory cost data 296. The extracted inventory cost record group is one or more inventory cost records containing the same inventory identifier as the inventory identifier in the updated dwell time record. Next, the inventory cost calculation unit 230 calculates the total inventory cost in the extracted inventory cost record group. The calculated total is referred to as "total cost”. Next, the inventory cost calculation unit 230 selects a manufacturing process record including the same inventory identifier as the inventory identifier in the updated residence time record from the manufacturing process data 294. Then, the inventory cost calculation unit 230 updates the inventory cost of the selected manufacturing process record to the calculated total cost.
  • the details of the inventory cost display processing (S140) will be described.
  • the inventory cost display unit 240 generates the data of the inventory cost graph 111 using the inventory cost data 296, and displays the inventory cost graph 111 on the display 102 using the generated data.
  • the inventory cost display unit 240 generates the data of the inventory cost graph 111 as follows.
  • the inventory cost display unit 240 extracts a group of inventory cost records from the inventory cost data 296 for each inventory identifier.
  • the extracted inventory cost record group is one or more inventory cost records containing the same inventory identifier.
  • the inventory cost display unit 240 generates a graph showing the inventory cost of each stage shown in the inventory cost record group for each inventory identifier.
  • the inventory cost display unit 240 generates data representing a graph for each inventory identifier.
  • the generated data is the data of the inventory cost graph 111.
  • FIG. 13 shows a specific example of the inventory cost graph 111.
  • the inventory cost graph 111 shows the inventory cost of each stage for each inventory.
  • the inventory cost graph 111 is a bar graph showing the inventory cost of each stage for each inventory.
  • the inventory cost graph 111 shows the inventory cost of each stage of the material, process 1, process 1 and 2, and process 2 for each inventory. Steps 1 and 2 mean between steps 1 and 2.
  • the inventory of each of the inventory identifier "1", the inventory identifier "2", and the inventory identifier "3" is the in-process inventory in step 2.
  • the inventory cost graph 111 shows the inventory cost at the material stage and
  • the inventory of the inventory identifier "4" is the inventory of steps 1 and 2.
  • the inventory of the inventory identifier “5” is the in-process inventory of step 1.
  • FIG. 14 shows a manufacturing process flow for the finished inventory (3000).
  • the finished inventory (3000) is manufactured by Step 1, Step 2, Step 3, Step 4, and Step 5.
  • FIG. 15 shows the manufacturing process of the finished inventory (3000).
  • the finished stock (3000) is manufactured by processing the material stock (0001) and the material stock (0204).
  • An inventory identifier is assigned to each material inventory.
  • An inventory identifier "0001" was assigned to one of the material inventories processed in step 1.
  • An inventory identifier "0204" was assigned to one of the material inventories processed in step 3.
  • the material inventory (0001) is processed in step 1 to become the inter-process inventory (0001) in the pre-process of process 2, and the inter-process inventory (0001) is processed in step 2 to become the inter-process inventory (0001) in the pre-process of process 4. It becomes (0001).
  • the material inventory (0204) is processed in the process 3 to become the inter-process inventory (0204) in the previous stage of the process 4. After that, step 4 is performed.
  • the inter-process inventory (0001) and the inter-process inventory (0204) are combined.
  • a new inventory identifier is assigned to the inter-process inventory obtained in step 4. For example, the inventory identifier "3000" is assigned.
  • the inventory cost calculation unit 230 may calculate the inventory cost in consideration of the interest rate. For example, in step S130 of FIG. 10, an interest rate added in proportion to the residence time of each inventory in each stage may be added.
  • the inventory cost per piece or production lot generated inside and outside the factory can be calculated in real time.
  • the inventory cost per production lot can be calculated.
  • the inventory cost of each stage can be visualized for each inventory.
  • the factory manager can find an abnormality in the cost of a certain inventory by looking at the inventory cost graph 111 displayed on the display 102. For example, an administrator can discover the anomaly that the cost of one inventory is significantly higher than the cost of another. It is assumed that the inventory cost graph 111 of FIG. 13 is displayed on the display 102. In this case, the manager notices that the cost required in steps 1 and 2 for the inventory of the inventory identifier "2" is larger than the cost of other inventory. It is considered that the cause of this is that the inventory is retained between the process 1 and the process 2. That is, it is considered that the cause is that the process 1 and the process 2 are not balanced.
  • the work time of the process 1 may be shorter than the work time of the process 2, or the number of production lot units in the process 1 may be larger than the number of production lot units in the process 2.
  • the administrator adjusts the working time of process 1 or the number of production lot units to be input to process 1.
  • the working time of step 1 can be adjusted, for example, by the amount of inventory to be put into step 1.
  • the inventory cost calculation device 200 does not operate only at a specific time such as the end of a quarter, but always operates in real time. Therefore, the factory manager can always know the latest inventory cost through the display 102. Therefore, managers can take actions to reduce inventory costs at any time, not just at specific times, such as at the end of the quarter.
  • Embodiment 2 The form of calculating the total inventory cost of each stage for each product type will be described mainly different from the first embodiment with reference to FIGS. 16 to 28.
  • the configuration of the inventory cost calculation system 100 includes a total cost calculation device 300 and a display 103 in addition to the elements described in the first embodiment (see FIG. 1).
  • the total cost calculation device 300 communicates with the inventory cost calculation device 200 via a network.
  • the display 103 is connected to the total cost calculation device 300.
  • the total cost calculation device 300 calculates the total cost of each stage for each product type.
  • the total cost is the total cost of inventory of finished stock belonging to the same product type. Further, the total cost calculation device 300 displays a graph showing the total cost of each stage for each product type on the display 103.
  • the configuration of the total cost calculation device 300 is a computer including hardware such as a processor 301, a memory 302, an auxiliary storage device 303, a communication device 304, and an input / output interface 305. These hardware are connected to each other via signal lines.
  • the processor 301 is an IC that performs arithmetic processing and controls other hardware.
  • processor 301 is a CPU, DSP or GPU.
  • the memory 302 is a volatile or non-volatile storage device.
  • the memory 302 is also referred to as a main storage device or a main memory.
  • the memory 302 is a RAM.
  • the data stored in the memory 302 is stored in the auxiliary storage device 303 as needed.
  • the auxiliary storage device 303 is a non-volatile storage device.
  • the auxiliary storage device 303 is a ROM, HDD, or flash memory.
  • the data stored in the auxiliary storage device 303 is loaded into the memory 302 as needed.
  • the communication device 304 is a receiver and a transmitter.
  • the communication device 304 is a communication chip or NIC.
  • the input / output interface 305 is a port to which an input device and an output device are connected.
  • the input / output interface 305 is a USB terminal
  • the input device is a keyboard and a mouse
  • the output device is a display 103.
  • the total cost calculation device 300 includes elements such as a general-purpose data reception unit 310, a product type determination unit 320, a total cost calculation unit 330, and a communication device 304. These elements are realized in software.
  • the auxiliary storage device 303 stores a total cost calculation program for operating the computer as a general-purpose data reception unit 310, a product type determination unit 320, a total cost calculation unit 330, a total cost calculation unit 330, and a total cost display unit 340. ing.
  • the total cost calculation program is loaded into the memory 302 and executed by the processor 301.
  • the OS is further stored in the auxiliary storage device 303. At least part of the OS is loaded into memory 302 and executed by processor 301.
  • the processor 301 executes the total cost calculation program while executing the OS.
  • the input / output data of the total cost calculation program is stored in the storage unit 390.
  • the memory 302 functions as a storage unit 390.
  • a storage device such as an auxiliary storage device 303, a register in the processor 301, and a cache memory in the processor 301 may function as a storage unit 390 instead of the memory 302 or together with the memory 302.
  • the total cost calculation device 300 may include a plurality of processors that replace the processor 301.
  • the plurality of processors share the functions of the processor 301.
  • the total cost calculation program can record (store) in a non-volatile recording medium such as an optical disk or a flash memory so that it can be read by a computer.
  • a non-volatile recording medium such as an optical disk or a flash memory
  • the configuration of the storage unit 390 will be described with reference to FIG.
  • the storage unit 390 stores product type data 391, manufacturing process data 294, completed inventory group data 392, inventory cost data 296, total cost data 393, and the like.
  • the product type data 391 indicates a product type corresponding to each of the plurality of manufacturing process flows.
  • the product type is the type of finished product (product) obtained by the manufacturing process flow.
  • the product type data 391 is a table in which the manufacturing process information and the type identifier are associated with each other.
  • the type identifier identifies the product type.
  • the combination of manufacturing process information and product type is called a "product type record”.
  • the completed inventory group data 392 will be described with reference to FIG.
  • the completed inventory group data 392 shows the completed inventory group belonging to each product type.
  • a finished stock group is one or more finished stocks belonging to the same product type.
  • the completed inventory group data 392 is a table in which the type identifier and the inventory group information are associated with each other.
  • the inventory group information is information indicating a completed inventory group, and is represented by one or more inventory identifiers corresponding to one or more completed inventory belonging to the same product type.
  • the set of the type identifier and the inventory group information is referred to as a "completed inventory group record".
  • the total cost data 393 will be described with reference to FIG.
  • the total cost data 393 shows the total cost of each stage for each product type.
  • the total cost data 393 is a table in which the type identifier, the stage identifier, and the total cost are associated with each other.
  • a set of a type identifier, a stage identifier, and a total cost is called a "total cost record".
  • the procedure for operating the total cost calculation device 300 corresponds to the total cost calculation method.
  • the total cost calculation method is a part of the inventory cost calculation method by the inventory cost calculation system 100.
  • the operation procedure of the total cost calculation device 300 corresponds to the processing procedure by the total cost calculation program.
  • the total cost calculation program is a part of the inventory cost calculation program for the inventory cost calculation system 100.
  • step S210 the user inputs the product type data 391 into the total cost calculation device 300.
  • the general-purpose data receiving unit 310 receives the product type data 391. Then, the general-purpose data receiving unit 310 stores the product type data 391 in the storage unit 390.
  • step S220 the product type determination unit 320 determines the product type of each finished inventory based on the manufacturing process data 294 and the product type data 391. The details of the product type determination process (S220) will be described later.
  • step S230 the total cost calculation unit 330 calculates the total cost of each stage for each product type based on the product type of each finished inventory and the inventory cost of each stage for each finished inventory. The details of the total cost calculation process (S230) will be described later.
  • step S240 the total cost display unit 340 displays a graph showing the total cost of each stage for each product type. The details of the total cost display processing (S240) will be described later.
  • step S221 the product type determination unit 320 acquires the manufacturing process data 294. Specifically, the product type determination unit 320 receives the manufacturing process data 294 from the inventory cost calculation device 200. Then, the product type determination unit 320 stores the manufacturing process data 294 in the storage unit 390.
  • step S222 the product type determination unit 320 selects one unselected manufacturing process record from the manufacturing process data 294.
  • step S223 the product type determination unit 320 searches the product type data 391 for the product type record corresponding to the selected manufacturing process record.
  • the product type record corresponding to the selected manufacturing process is a product type record containing the same manufacturing process information as the manufacturing process information in the selected manufacturing process record.
  • the product type record corresponding to the selected manufacturing process is referred to as "the product type record”.
  • step S224 The product type identified by the type identifier in the product type record is the identified product type. If the product type record is not found, the process proceeds to step S225.
  • step S224 the product type determination unit 320 updates the completed inventory group record corresponding to the product type record.
  • the product type determination unit 320 operates as follows. First, the product type determination unit 320 selects a completed inventory group record including the same type identifier as the type identifier in the product type record from the completed inventory group data 392. Then, the product type determination unit 320 adds the same inventory identifier as the inventory identifier in the manufacturing process record selected in step S222 to the inventory group information in the selected completed inventory group record. However, if the same inventory identifier as the inventory identifier in the selected manufacturing process record is included in the inventory group information in the selected completed inventory group record, it is not necessary to add the inventory identifier.
  • the product type determining unit 320 When the completed inventory group record corresponding to the product type record does not exist, the product type determining unit 320 generates the completed inventory group record and registers the generated completed inventory group record in the completed inventory group data 392.
  • the type identifier in the completed inventory group record to be registered is the same as the type identifier in the product type record.
  • the inventory group information in the completed inventory group record to be registered indicates the same inventory identifier as the inventory identifier in the manufacturing process record selected in step S222.
  • step S225 the product type determination unit 320 determines whether or not there is an unselected manufacturing process record in the manufacturing process data 294. If there are unselected manufacturing process records, the process proceeds to step S222. If there are no unselected manufacturing process records, the process ends.
  • step S231 the total cost calculation unit 330 acquires inventory cost data 296. Specifically, the total cost calculation unit 330 receives the inventory cost data 296 from the inventory cost calculation device 200. Then, the total cost calculation unit 330 stores the inventory cost data 296 in the storage unit 390.
  • step S232 the total cost calculation unit 330 selects one unselected completed inventory group record from the completed inventory group data 392.
  • step S233 the total cost calculation unit 330 extracts the inventory cost record group corresponding to the selected completed inventory group record from the inventory cost data 296.
  • the extracted inventory cost record group is one or more inventory cost records including the same inventory identifier as each inventory identifier included in the inventory group information in the selected completed inventory group record.
  • step S234 the total cost calculation unit 330 extracts the product type record corresponding to the selected completed inventory group record from the product type data 391.
  • step S235 the total cost calculation unit 330 selects one unselected stage identifier from the manufacturing process information in the selected product type record.
  • step S236 the total cost calculation unit 330 calculates the total cost of the stage identified by the selected stage identifier for the product type shown in the selected product type record.
  • the total cost calculation unit 330 operates as follows. First, the total cost calculation unit 330 extracts one or more inventory cost records corresponding to the selected stage identifier from the inventory cost record group extracted in step S233. Each inventory cost record extracted contains the same stage identifier as the selected stage identifier. Next, the total cost calculation unit 330 extracts the inventory cost from each of the extracted inventory cost records. Next, the total cost calculation unit 330 calculates the total of the extracted inventory costs. The calculated total is the total cost. Then, the total cost calculation unit 330 generates a total cost record and registers the generated total cost record in the total cost data 393. The type identifier in the total cost record to be registered is the same as the type identifier in the product type record extracted in step S234. The stage identifier in the total cost record to be registered is the same as the stage identifier selected in step S235. The total cost in the registered total cost record is the same as the total cost calculated in step S236.
  • step S237 the total cost calculation unit 330 determines whether or not there is an unselected stage identifier in the manufacturing process information of the product type record extracted in step S234. If there is an unselected stage identifier, the process proceeds to step S235. If there is no unselected stage identifier, the process proceeds to step S238.
  • step S2308 the total cost calculation unit 330 determines whether there is an unselected completed inventory group record in the completed inventory group data 392. If there is an unselected completed inventory group record, the process proceeds to step S232. If there are no unselected completed stock group records, the process ends.
  • the total cost display unit 340 generates the data of the total cost graph 112 using the total cost data 393, and causes the display 103 to display the total cost graph 112 using the generated data.
  • the total cost display unit 340 generates the data of the total cost graph 112 as follows.
  • the total cost display unit 340 extracts a total cost record group from the total cost data 393 for each type identifier.
  • the extracted total cost record group is one or more total cost records containing the same type identifier.
  • the total cost display unit 340 generates a graph showing the total cost of each stage shown in the total cost record group for each type identifier.
  • the total cost display unit 340 generates data representing a graph for each type identifier.
  • the generated data is the data of the total cost graph 112.
  • FIG. 25 shows a specific example of the total cost graph 112.
  • the total cost graph 112 shows the total cost of each stage for each product type.
  • the total cost graph 112 is a bar graph showing the total cost of each stage for each product type.
  • the total cost graph 112 shows the inventory cost of each stage of the material, the process 1, the process 1 and 2, the process 2, and the finished product for each product type. Steps 1 and 2 mean between steps 1 and 2.
  • FIG. 26 shows two types of manufacturing process flows for the material inventory (0001).
  • the material inventory (0001) is processed in the order of step 1, step 2, step 4 and step 5.
  • the material inventory (0001) is processed in the order of step 1, step 2, step 4, step 5 and step 6.
  • the types of products to be manufactured differ between the first manufacturing process flow and the second manufacturing process flow.
  • the total cost calculation unit 3300 may calculate the total cost in consideration of the interest rate.
  • the product type may be determined according to the combination of the type of material inventory and the type of manufacturing process flow. In this case, the product type is determined as follows. The points different from the above description will be mainly described.
  • the general-purpose data receiving unit 310 receives the product type data 391 and the material data 394.
  • Product type data 391 will be described with reference to FIG. 27.
  • the product type data 391 indicates the product type for each combination of the material inventory type and the manufacturing process flow type.
  • the product type data 391 is a table in which the material identifier, the manufacturing process information, and the type identifier are associated with each other.
  • the material identifier identifies the type of material.
  • the set of the material identifier, the manufacturing process information, and the type identifier is called a "product type record”.
  • Material data 394 will be described with reference to FIG. 28.
  • Material data 394 indicates the type of each material inventory.
  • the material data 394 is a table in which an inventory identifier and a material identifier are associated with each other.
  • the set of the inventory identifier and the material identifier is called a "material record”.
  • the product type determination unit 320 extracts the material record corresponding to the selected manufacturing process record from the material data 394.
  • the material record extracted contains the same inventory identifier as the inventory identifier in the selected manufacturing process record.
  • the product type determination unit 320 searches for the product type record corresponding to the selected manufacturing process record and the extracted material record from the product type data 391.
  • the product type record contains the same manufacturing process information as the manufacturing process information in the selected manufacturing process record, and includes the same material identifier as the material identifier in the extracted material record.
  • the product type identified by the type identifier in the product type record is the identified product type.
  • the inventory cost for each product type can be calculated in real time.
  • the inventory cost at each stage can be visualized for each product type.
  • the factory owner can find an abnormality in the cost of a certain product type by looking at the total cost graph 112 displayed on the display 103.
  • management can discover the anomaly that the cost of one stage of a product type is significantly higher than the cost of another product type. It is assumed that the total cost graph 112 of FIG. 25 is displayed on the display 103.
  • the management notices that the cost of the finished product of the product type "A” and the cost of the material of the product type "C" are large. It is considered that the cause of this is an excessive inventory of the finished product of product type "A" and the material of product type "C".
  • the production lead time of product type "A” is shorter than the transportation lead time
  • the safety stock quantity of finished products of product type “A” is set higher than necessary
  • the safety of materials of product type "C" The cause may be that the number of stocks is set higher than necessary.
  • the rough inventory cost for each product type can be calculated without calculating the inventory cost per piece or production lot. However, it is difficult to consider the time that inventory stays at each stage based on the rough inventory cost. On the other hand, by totaling the inventory costs calculated per piece or per production lot for each product type, it is possible to calculate a highly accurate inventory cost that can take such time into consideration. Then, based on the highly accurate inventory cost, it is possible to take an action to suppress the inventory cost. Therefore, it is possible to take an action that is more effective than an action based on a roughly calculated inventory cost.
  • the total cost calculation device 300 does not operate only at a specific time such as the end of the quarter, but always operates in real time. Therefore, the factory owner can always see the latest inventory cost through the display 103. Therefore, the management can take actions to reduce the inventory cost incurred in the entire factory at any time, not only at a specific time such as the end of the quarter.
  • the inventory cost calculation device 200 includes a processing circuit 209.
  • the processing circuit 209 is hardware that realizes a general-purpose data reception unit 210, a residence time measurement unit 220, an inventory cost calculation unit 230, an inventory cost display unit 240, and a storage unit 290.
  • the processing circuit 209 may be dedicated hardware or a processor 201 that executes a program stored in the memory 202.
  • the processing circuit 209 is dedicated hardware, the processing circuit 209 is, for example, a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC, an FPGA, or a combination thereof.
  • ASIC is an abbreviation for Application Special Integrated Circuit.
  • FPGA is an abbreviation for Field Programmable Gate Array.
  • the inventory cost calculation device 200 may include a plurality of processing circuits that replace the processing circuit 209.
  • the plurality of processing circuits share the functions of the processing circuit 209.
  • the inventory cost calculation device 200 some functions may be realized by dedicated hardware, and the remaining functions may be realized by software or firmware.
  • each function of the inventory cost calculation device 200 can be realized by hardware, software, firmware, or a combination thereof.
  • the total cost calculation device 300 includes a processing circuit 309.
  • the processing circuit 309 is hardware that realizes a general-purpose data reception unit 310, a product type determination unit 320, a total cost calculation unit 330, a total cost display unit 340, and a storage unit 390.
  • the processing circuit 309 may be dedicated hardware or a processor 301 that executes a program stored in the memory 302.
  • the processing circuit 309 is dedicated hardware, the processing circuit 309 is, for example, a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC, an FPGA, or a combination thereof.
  • the total cost calculation device 300 may include a plurality of processing circuits that replace the processing circuit 309.
  • the plurality of processing circuits share the functions of the processing circuit 309.
  • the total cost calculation device 300 some functions may be realized by dedicated hardware, and the remaining functions may be realized by software or firmware.
  • each function of the total cost calculation device 300 can be realized by hardware, software, firmware, or a combination thereof.
  • Each embodiment is an example of a preferred embodiment and is not intended to limit the technical scope of the present invention. Each embodiment may be partially implemented or may be implemented in combination with other embodiments. The procedure described using the flowchart or the like may be appropriately changed.
  • the functions of both the inventory cost calculation device 200 and the total cost calculation device 300 may be realized by one computer.
  • the "part”, which is an element of each of the inventory cost calculation device 200 and the total cost calculation device 300, may be read as “processing” or "process”.
  • the inventory identifier may be attached to each inventory or to each lot.
  • a lot is a group of multiple products that flow through a process, and there are various forms of lots.
  • one cassette is referred to as "one inventories" after that process.
  • the process flows one by one, but when the inventory is input to the first process in a batch, the group of the plurality of inventory to be input to the first process is "lot”. There is an example called.
  • 100 inventory cost calculation system 101 inventory detection sensor, 102 display, 103 display, 111 inventory cost graph, 112 total cost graph, 200 inventory cost calculation device, 201 processor, 202 memory, 203 auxiliary storage device, 204 communication device, 205 Output interface, 209 processing circuit, 210 general-purpose data reception unit, 220 residence time measurement unit, 221 retention stage data, 230 inventory cost calculation unit, 240 inventory cost display unit, 290 storage unit, 291 consumption data, 292 unit price data, 293 Sensor management data, 294 manufacturing process data, 295 residence time data, 296 inventory cost data, 300 total cost calculation device, 301 processor, 302 memory, 303 auxiliary storage device, 304 communication device, 305 input / output interface, 309 processing circuit, 310 General-purpose data reception unit, 320 product type determination unit, 330 total cost calculation unit, 340 total total cost display unit, 390 storage unit, 391 product type data, 392 completed inventory group data, 393 total total cost data, 394 material data.

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Abstract

Dans la présente invention, des capteurs de détection d'inventaire sont installés à chacun des emplacements suivants : un emplacement où l'inventaire à l'étape avant le traitement sur la base d'un flux de processus de fabrication qui comprend de multiples processus de fabrication reste ; un emplacement où l'inventaire à l'étape de traitement dans chacun des processus de fabrication reste ; un emplacement où l'inventaire à l'étape d'attente de traitement entre les processus de fabrication reste ; et un emplacement où l'inventaire à l'étape après le traitement sur la base du flux de processus de fabrication reste. Une unité de mesure de temps de séjour (220) mesure le temps de séjour de chaque inventaire au niveau de chacune des étapes à l'aide des capteurs de détection d'inventaire. Une unité de calcul de coût d'inventaire (230) calcule le coût d'inventaire pour chaque inventaire au niveau de chacune des étapes sur la base du temps de séjour de chaque inventaire au niveau de chacune des étapes.
PCT/JP2019/043444 2019-11-06 2019-11-06 Système de calcul de coût d'inventaire, procédé de calcul de coût d'inventaire et programme de calcul de coût d'inventaire Ceased WO2021090392A1 (fr)

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JP2020528352A JP6779417B1 (ja) 2019-11-06 2019-11-06 在庫費算出システム、在庫費算出方法および在庫費算出プログラム
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