JP2771014B2 - production management system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION "Industrial application field" The present invention is used, for example, in an automobile production line or the like that mixes and produces different types of machines, and distributes information of processing contents using a network, and The present invention relates to a production management system that instructs processing such as welding for each model for each unit and executes the processing.

2. Description of the Related Art In a production line or the like, a processing machine is arranged at a predetermined position and performs various processes on a workpiece moving along the line. By the way, when different types of vehicles and the like are produced on the same line as in the case of an automobile production line, each processing machine must perform processing according to the types of vehicles and the like. Further, it is necessary to perform a process of converting the processing order information into a model pattern for performing a process corresponding to the type of the machine of each processing machine. Furthermore, since the information on the processing order is mixed and complicated, it is necessary to perform processing for organizing and collecting the information into the information of each processing machine.

For this reason, as shown in FIG. 6, the operator in the conventional machining process first organizes and summarizes the information of the machining order into order data of each machining process, as shown in FIG. After converting the data into a model pattern, the model pattern is input to the processing machine, and the work is set on the processing machine based on the ranking data. These are the first and second conversion processes by a person. The ranking data is based on the model (year, manufacturing factory, 2
Doors, 4 doors, etc.), derivation (grade), options (presence / absence of sunroof, etc.), rod numbers (numbers assigned for each predetermined number), numerical values for the predetermined number, etc., are arranged according to the processing order. It is a thing. On the other hand, the processing machine is arranged in the area of the production line, and when a model pattern is input by an operator, a code for determining an operation is created using a conversion table stored therein, and according to the code, Perform processing. This is the third conversion processing by (M / C). The code includes the number and operation pattern of the processing jig, the job number (operation pattern, welding condition number, etc.) of the robot, and the like.

For example, in a processing step of welding a side panel to a floor panel, information of a processing order is converted into order data of the processing step, and further converted into a model pattern,
Input to the processing machine. After that, based on the ranking data, take out the side panel suitable for the model, derivation, etc. from the mounting place and set it on the jig, while the processing machine creates the code for deciding the operation based on the model pattern Weld necessary parts to the floor panel and assemble the floor panel and side panel.

In addition, the work of converting the order information into the model pattern in which the order data is aggregated into the processing process unit is changed when the model change of the vehicle type or the like occurs. Provide education. Further, when the processing information is changed due to an order from a user, reprocessing, or the like, the changed order information is transmitted to the processing step each time.

[Problems to be Solved by the Invention] However, in such a conventional production line, in each processing step arranged in the line area, an operator (person) performs conversion and aggregation of the processing order table. As a result, human errors occur, the efficiency of production management is low, and the number of man-hours is increased despite the automation line.

In addition, the aggregation of the processing order table, the conversion work, for example, there are model year model, model-specific code, derivative-specific code, option-specific code, M / C operation pattern code, etc. It becomes complicated, man-hours increase, and the efficiency of production management is poor.

In addition, the work of aggregation and conversion of ranking information is changed due to model change of the model, etc., but in the case of car lines that produce different models, model change of the model is complicated, so every time the model is changed, The number of man-hours for training the operators to be performed increases, and the efficiency of production management decreases. Further, the order information is changed by an order received from a user, reworked, or the like, but the order information has been frequently changed due to factors such as a reduction in manufacturing lead time in recent years. At this time, every time a change is made, it is necessary to transmit the contents of the change of the order information to each process, so that the flow of the entire production management is not smooth and the efficiency is reduced.

Therefore, the present invention enables the reduction of man-hours of the operator, realizes the construction of an efficient automation line system without increasing the burden on the operator even when the number of production models increases, and realizes the efficiency of production management. The purpose is to provide a production management system that can enhance the production.

[Means for Solving the Problems] In order to achieve the above object, the production management system according to the present invention, as shown in FIG. A production line b that conveys between processing steps in a predetermined order for each predetermined number
And a higher-level controller for setting and storing processing contents for each predetermined number of models, each derivative, and the like for the workpiece a on the production line b, and distributing information of the processing contents using a network. c, a conversion file that divides the information of the processing order into machine-derived sections for each processing step of the production line b, and a middle-level controller d that distributes the conversion file to the higher-level controller c; Processing order information and a conversion file are received from the controller c, and the processing order information is converted into processing instruction information for each processing step based on the conversion file and aggregated, and processing instructions corresponding to the processing contents of the workpiece are processed. And a predetermined number of workpieces a which are arranged in the area of the production line b, and , Characterized in that it was Preparations and machining execution means f for executing by a predetermined processing line corresponding to the model derived for each such in that order.

In a preferred embodiment, the lower controller e sets a model-specific derivation aggregation code for each line as a file for conversion and aggregation into processing information for each line distributed from the upper controller c, At least one of setting of option code for each line, setting of M / C operation pattern code for each line, setting of work material code for each line, setting of representative value of consolidated code for each line It is characterized by including.

[Operation] In the present invention, the contents of processing are set for the workpiece a by the upper controller c for each predetermined number of models and for each derivation of the workpiece a. Distributed to the controller e. In addition, a conversion file is created in the middle controller d that is classified into machine type derivation sections for each machining process, and the conversion file is distributed to the upper controller c. Processing instructions for processing orders of different models, different derivatives, etc., are analyzed and aggregated by the lower controller e, and given to the processing execution means f for each line, and predetermined instructions corresponding to each model, each derivative, etc., for each line. Is performed.

Therefore, the files for analyzing and consolidating the processing contents and lines for the workpiece a by the line are managed collectively by the upper controller c, and the man-hours for inputting or changing the processing order and file data are reduced. Aggregation of processing information for each line by the lower-order controller e enhances data management efficiency, significantly improving processing efficiency, and improving production management efficiency.

Hereinafter, the present invention will be described with reference to the drawings.

2 to 5 are diagrams showing an embodiment of the production management system according to the present invention.

First, the configuration will be described. FIG. 2 is a schematic configuration diagram showing a network in a welding section of an automobile production line to which the present invention is applied. In this figure, 1 is a host computer (upper controller) as a processing order file computer, 2C, 2D, and 2E are derived centralized maintenance computers (middle controller), 2A and 2B are line area computers (lower controller), Reference numerals 3 and 3A denote networks. For example, 3 has a total of 44 nodes as nodes, and 3A has 6 communication terminals. 4A to 4X are terminal sequencers (processing execution means)
And a welding robot for performing a welding process. 5
In a production line, each body (workpiece) 6 including a different model is placed on a transport trolley (not shown) and transported by a predetermined number of units in a predetermined order from a loading section to a delivery section. As shown in FIG. 5 described later, the production line 5 is provided with a number of lines 203 to 212 for each welding process, and processing information is collected for each line.

The host computer 1 receives, for example, weekly processing order data from the external computer 1A, checks a seam of the processing order data, stores the data, distributes the processing order data to the line area computers 2A and 2B, and adds the data for each line. Distribute files for aggregating information.
That is, for each body 6 on the production line 5, the processing order is set and stored for each predetermined number of models and for each model derivation, and a conversion file for pre-aggregation is distributed using the network 3 before the processing. Distribute ranking information.
As the aggregation setting of processing information for each line, for example, setting of a model-specific aggregation code for each line, setting of an option code for each line, and setting of an
It sets the M / C operation pattern code, sets the work material code for each line, and sets the representative value of the consolidated code for each line. The model-specific derivation aggregation code is a code with a large digit to identify the type of vehicle and to indicate two-door, four-door, overseas, domestic, etc. In some cases, the derived aggregate code for each model is simplified until it can be used in a line.

A predetermined number of the bodies 6 are arranged on the production line 5 in a predetermined order, and the processing content for each body 6 is determined and loaded in the host computer 1 in advance, for example, on a weekly basis. Further, the information of the host computer 1 is transferred in a constantly communicating state to 2E, one of the derivative centralized maintenance computers, through the personal computer network 3A to back up the data. In other words, 2E, one of the derivative centralized maintenance computers, stores data and has an alternative function. Further, the switching to the alternative machine is performed by the switching device 10. Further, the derivative aggregation maintenance computers 2C, 2D, and 2E create a conversion file that divides the information of the processing order into a model derivation section for each processing step of the production line 5 and distributes the conversion file to the host computer 1. Further, the converted file delivered to the host computer 1 is backed up at the same level by 2E, which is one of the derivative aggregation maintenance computers in a constantly communicating state. That is, the host computer 1 stores data as a function of a file server, and 2E, which is one of the derivative centralized maintenance computers, stores data of the host computer 1 at the same level as an alternative function. Also,
Among the derivative aggregate maintenance computers, 2C and 2D have a function of converting processing order information into processing instruction information, which will be described later, as an alternative function to the line area computers 2A and 2B. That is, in the derivative aggregate maintenance computers 2C and 2D, the functions as the line area computers are satisfied after the processing order information is distributed from the host computer 1 by replacing the line area computers 2A and 2B. .
The host computer 1 has a disk drive device 11, a printer 12, a keyboard 13 and a CRT display 14 as attached devices, and the same applies to the other derivative centralized maintenance computer 2E (others are not shown).

The information from the derivative aggregation maintenance computers 2C and 2D is stored once in the host computer 1 and then input to the line area computers 2A and 2B via the network 3A. Receiving the conversion file, converting the processing order information into processing instruction information for each processing step based on the conversion file, and transmitting a processing instruction corresponding to the processing content for each different model, each derivative, etc. for each body 6 in a line. Separately, the data is output to the sequencers 4A to 4X via the network 3. The derivative centralized maintenance computer 2C has a disk drive 21, a printer 22, a keyboard 23 and
It has a CRT display 24, which is the same for the other derivative integrated maintenance computer 2D and the line area computers 2A, 2B (others are not shown). Reference numeral 25 denotes a transceiver of the personal computer network 26, and other transceivers are omitted from the coding in order to avoid complication.

The sequencers 4A to 4X are arranged in the area of the production line 5, and correspond to each model derivation in the order in which the predetermined number of the bodies 6 are arranged in accordance with the processing instructions from the line area computers 2A and 2B. Is performed for each line.

Here, the network of the processing instruction system can be easily understood as shown in FIG. In the figure, 1A is an external computer that performs information processing such as creation of weekly processing order data, 1 is a processing order file computer as a host computer, 2C, 2D, and 2E are derived aggregate maintenance computers, 2A and 2B are line area computers, 2G is a performance monitor computer, 2H is a performance data collection controller, and 4A to 4X are M / C controllers as sequencers.

31 to 35 are performance monitor computers, which are arranged in, for example, an office, a maintenance department, a planning room, a retrieval room, and the like, and display processing results in real time. The performance monitor computer 31 is composed of a main body 41, a printer 42, a keyboard 43, and a CRT.
It has a display 44, which is the same for other performance monitoring computers (otherwise, omitting the sign). 51 is a line server in the network 3 and 52 is a power supply device.

The information handled by the network 3 includes the following information.

Machining instruction Actual number of machines Line stop time Line tact: Machining time per unit number Flow between lines: Relationship between the cumulative number of own process and the cumulative number of next process.

Line automatic operation signal: Includes channel, manual, and abnormal signals.

Maintenance notification signal Construction notification signal Line status signal Next, the operation of this embodiment with the above configuration will be described.

In the production process for welding, first an external computer
For example, the processing contents (particularly, processing order) of the body 6 are determined and sent in units of one week from the host computer 1 to the host computer 1, and are loaded in the host computer 1 in advance. This information is set and supplemented for each body 6 on the production line 5 for each predetermined number of models and for each model, and is distributed to the line area computers 2A and 2B via the personal computer network 3A. The information includes, for example, the model of the body 6 (the model name of the body and 4 doors, 2
Door information), derivative information (destination country, destination: cold district, etc.), optional information (sun roof presence / absence, etc.), etc. are included. These correspond to, for example, a model-specific derived aggregate code for each line, an option code for each line, and the like.

In addition, the setting of the model-specific derivative aggregation code for each line is performed by the derivative aggregation maintenance computers 2C, 2D, and 2E. In particular, the processing order information is classified into a model derivation section for each machining process of the production line 5, and the like. This conversion file is created as a file, distributed to the host computer 1, stored in the host computer 1 as setting data, and further distributed to the line area computers 2A and 2B.

Next, the processing order information from the host computer 1 is analyzed by the line area computers 2A and 2B from the host computer 1 using the conversion file, and processing instructions corresponding to the processing contents of each body 6 for different models are sequenced by the sequencers 4A to 4B.
Output to 4X. On the other hand, on the production line 5, each body 6 including a different model is placed on a transport trolley from its input section to the output section, and is transported between the processing steps in a predetermined order every predetermined number. . Then, a predetermined number of each body 6 placed on the production line 5 by the sequencers 4A to 4X based on the processing instructions collected by line.
In contrast, in the arranged order, predetermined welding processes corresponding to each model, each derivative, etc. are executed for each line.

Here, the processing of the derived aggregated data management system is performed, for example, as follows.

In the derived aggregate code setting process, the derived aggregate code is set for each node (line), and the model pattern data and model pattern representative are automatically entered when a new derived aggregate code is input based on the screen of the computer performing this process. Data is created. In the model pattern display representative selection processing, display of model pattern data and its representative setting are performed, and there is one representative in the same model pattern. In the option code name setting process, an option instruction code corresponding to the option code and an option name corresponding to the option instruction code are set. In the M / C model pattern setting process, the M / C model pattern in the derived aggregate code corresponding to the M / C model pattern on the site operation side is set. In the conversion table transmission processing, after transmitting the conversion files of the derivative aggregation file, the model pattern file, the model pattern conversion file, the M / C model pattern conversion file, the option code file, and the option name file to the line area computer, Send necessary data to other computers and sequencers. In the online display processing, the transmission state is displayed online on the conversion table transmission processing screen.

FIG. 4 shows a specific example of the welding process.
At 06, the rear frame, rear floor panel, front wheel house, front floor, rear floor, and front comp are assembled (component: COMP).
In step 107, the rear floor is inspected, and in steps 108 and 109, the rear floor, front floor, and front comp are respectively carried out. In step 110, the assembled parts are transported,
In step 111, the floor is assembled. Next, in step 112, processing of sub-main general welding (SMGW) is performed. Prior to this process, in steps 114 to 118, the 2F
Execute download (DL) to. That is, step 11
In step 4, the roof is lowered from 2F to 1F. In steps 115 and 116, the left and right sides of the rear inner panel are lowered. In steps 117 and 118, the left and right sides of the side panel are lowered. Step 11
At 9 and 120, lower the left and right of the pillar inner similarly. Next, in step 121, additional welding is performed on the sub main general welding, and similarly in step 122.
Performs additional beating by spot welding robot (SR).
Next, final MIG welding is performed in step 123, and if necessary, a spot welding supplementary step (supplementation step by a person in the event of a robot trouble) is performed in step 124, and a door or the like is attached in step 125. In steps 126 to 132, the bonnet is assembled, the trunk is assembled, the left and right front doors and the left and right rear doors are assembled, and the left and right huenders are assembled. Will be

FIG. 5 shows the state of each line in the production line 5, and lines 203 to 212 are provided around the management office 201 and the maintenance section 202 for each welding process.
In the figure, the black portions indicate locations where welding is automatically performed, the hatched portions indicate locations where welding is performed manually, and the white portions indicate locations where model change setup is performed. .

Considering the effect of this embodiment, the following is obtained.

(I) The processing content data for the body 6 and the conversion file for aggregation are collectively managed by the host computer 1, which is a higher-level controller, and distributed to the line area computers 2A and 2B, and then the processing information is aggregated. Therefore, unlike the conventional method where the operator collects the processing instruction data each time, the man-hour can be reduced for inputting or changing the processing order and the conversion file,
The efficiency of production management can be improved. In other words, the aggregation of processing information greatly improves the efficiency of data management, and can exhibit responsiveness even when the processing order or conversion file is changed, realizing the construction of a highly efficient automated line system. be able to.

That is, the processing of the processing data is improved by the aggregation of the processing number and the collective setting of the aggregation code in the derivation of the processing order data by line. For example, by creating a partial configuration list from the BOM (derived specification list), creating a model pattern, a derived pattern use list, and creating an M / C operation pattern use list, etc.
It is possible to improve the data availability (unity) by combining the processing order data and the M / C operation pattern, and to improve the data availability (unity) by combining the processing order data and the work material.

In addition, even if there is a change in the processing order, a change in the parts list, a change in the M / C operation pattern, etc., management of the change before and after these changes, management of the switching timing, and data storage are collectively performed by the host computer. By performing in step 1, the input of the change data is easy and the burden on the operator is reduced.

(II) In this embodiment, since the processing information is distributed and the files are stored and transmitted using the networks 3 and 3A, the reliability of the data receiving equipment is improved, the loss of the received data is prevented, and the duplication is prevented. Prevention can be achieved. In particular, the setting data from the derivative aggregation maintenance computer is stored on the file server, and the file server sends the setting data to the line area computer and the line area computer to the sequencer to set, store, and process the data. Since the functions are made independent, it is possible to improve operability and data reliability. In addition, there is flexibility in changing the processing order and converting the conversion file, always keeping only the latest data, ensuring the reliability of the data, and excellent in the maintainability of the data. When the number of communication lines of the network 3 is set to an appropriate number, an effect that the load on the network 3 can be reduced can be obtained.

(III) In the data processing, by performing the totaling of the number of pieces (processing of the processing order data) by collating the processing integrated data with the integrated code file, the data recognizability by the operator is improved. Further, by performing data processing by the middle controller, the data processing status of the middle controller can be monitored by the upper controller.

In the above embodiment, welding is performed as a process on a workpiece, but the present invention is not limited to this, and can be applied to other processes, such as assembly.
Further, the workpiece is not limited to the body of the vehicle, but may be another object.

In the above embodiment, the processing information for each line is aggregated by the middle controller, or the present invention is not limited to this, and may be performed by, for example, a higher controller.

[Effect] According to the present invention, processing order data for a workpiece,
The conversion files for aggregation are collectively managed by the upper controller, and the processing information is aggregated for each line in the middle controller using the processing order data distributed from the upper controller and the conversion file. Therefore, it is possible to reduce the number of man-hours for the operator, to improve the efficiency of data management by consolidating the processing information, and to greatly reduce the occurrence of human error. As a result, a highly efficient automated line system can be constructed, and the efficiency of production management can be increased. In addition, since the file is stored and transmitted, it is possible to improve the reliability of the data receiving facility, prevent loss of the received data, and prevent dubbing.

[Brief description of the drawings]

FIG. 1 is a basic conceptual diagram of the present invention, FIGS. 2 to 5 are diagrams showing an embodiment of a production management system according to the present invention, and FIG. 2 is a concept showing a network in a welding section of an automobile production line. FIG. 3 is a diagram schematically showing a computer network of the machining instruction system, FIG. 4 is a diagram showing specific steps of the welding process, FIG. 5 is a diagram showing a state of each production line, FIG. FIG. 6 is a diagram for explaining the processing order of the conventional production management system. 1 ... host computer (upper controller), 2C, 2D, 2E ... derived centralized maintenance computer (middle controller), 2A, 2B ... line area computer (lower controller), 3 ... network, 3A ... ... PC network, 4A ~ 4X ... Sequencer (processing means), 5 ... Production line, 6 ... Body (workpiece), 10 ... Switcher, 11, 21 ... Disk drive device, 12,22 , 42 ... Printer, 13,23,43 ... Keyboard, 14,24,44 ... CRT display, 25 ... Transceiver, 26 ... PC net, 31-35 ... Result monitor computer, 41 ... Main unit, 51: Line server, 52: Power supply device.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) G05B 15/02 G05B 19/418 G06F 17/60 B23Q 41/08

Claims (2)

(57) [Claims] 1. A production line for transporting workpieces including different types of machines from a feeding section to a delivery section in a predetermined order at a predetermined number of times between processing steps, and a predetermined number of workpieces on the production line. For each model,
Processing contents are set and stored for each model, and at the same time, a higher-level controller that distributes the processing contents information using a network, and the processing order information is classified into model-derived sections for each processing step of a production line. A conversion file to be created, and a middle-level controller that distributes the conversion file to a higher-order controller; information of a processing order from the higher-order controller; and a conversion file, and the information of the processing order is based on the conversion file. It is converted to processing instruction information for each processing step, aggregated, and a lower-level controller that gives processing instructions corresponding to the processing content of the workpiece by line, and a lower-level controller that is arranged in the area of the production line and receives processing instructions from the lower-level controller. Based on a predetermined number of workpieces based on the line, the specific processing corresponding to each model derivation, etc., in that order Production control system characterized by comprising: a stage, a. 2. The low-order controller sets a model-specific derivation aggregation code for each line as a file for conversion and aggregation into processing information for each line distributed from the upper controller, At least one of the following: option code setting, M / C operation pattern code setting for each line, work material code setting for each line, and representative value setting of aggregate code for each line The production management system according to claim 1, further comprising: