JP2771015B2 - 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 derivative, 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, the operator in the conventional machining process first sorts and summarizes the information on the machining order into order data of each machining process unit 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 machine arranged in the line area, an operator (person) collects and converts the processing order information. 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 each production line, the number of flows of the machining body between its own process and the next process, the accumulated number of machining in M / C (machine) machining, and the tact equivalent to the machining time per unit can be efficiently calculated by a computer or the like. I don't know
Since it relies solely on traffic, it is not possible to predict in advance the non-operation of the entire line in advance, and as a result, there is a problem that the operation rate of the entire line decreases.

In addition, the work of the aggregation and conversion of the ranking information changes depending on the model change of the vehicle type, etc.However, in the case of a car line that produces a different model, the model change of the vehicle type is complicated, so every change is required. 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. However, 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.

Accordingly, the present invention enables the reduction of man-hours of the operator, improves the operation rate of the entire line, increases the reliability of data, and realizes the construction of an efficient automated line system.
It is an object of the present invention to provide a production management system that can increase the efficiency of production management.

[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. For a plurality of production lines b that convey between processing steps for each predetermined number in a predetermined order, and for a workpiece a on the production line b, processing contents are set for each model, for each derivative, for each predetermined number, A higher-order controller c for storing and distributing the processing information through the network, and a conversion file for classifying the processing order information into model-derived sections for each processing step of the production line b are created. Controller c
Receiving the conversion file and the information of the processing content from the middle controller d and the higher controller c to be distributed to
The processing content information is converted and consolidated into processing instruction information for each processing step based on the conversion file, and a lower controller e for giving processing instructions, and a lower controller e arranged in each area of the plurality of production lines b, e, a processing execution unit f that executes predetermined processing corresponding to each line of each model in the processing order on a predetermined number of workpieces based on the processing instruction from e. A performance monitor controller that communicates data through a network, obtains the status of the next process and the number of machining flows between the own process and the next process, and distributes the process information through the network using data including at least the number of flows. g
And characterized in that:

In a preferred embodiment, the performance monitor controller g is configured to determine whether the process is automatic / manual, turn off,
Jig change signal and total number of units
It is characterized in that a tact corresponding to a processing time per unit number is received from a line of each process.

Further, the performance monitor controller g uses, as the flow number of machining between the own process and the next process, the calculation result of the cumulative number of machines finished in the own process and the total number of machines finished in the next process. It is characterized by.

[Operation] In the present invention, the contents of processing are set and stored for each predetermined number of models for the workpiece a by the upper controller c and distributed to the lower controller e using the network. In addition, a conversion file is created in the middle controller d that is divided into machine type derivation sections for each machining process, and the conversion file is delivered to the upper controller c, stored, and then delivered to the lower controller e. Processing instructions for processing orders for different models, different derivatives, etc. are analyzed and aggregated by the lower controller e,
The processing is given to the processing execution means f, and predetermined processing corresponding to each model, each derivation, and the like is performed. Further, the actual process monitor controller g obtains the status of the next process and the number of flows of machining between the own process and the next process, and information using at least data including the number of flows is distributed to the machining execution means f.

Therefore, the processing order data and the conversion file for the workpiece a are collectively managed by the upper controller c, and the processing result data processed by the collectively managed order data is managed by the result monitoring controller g. It is possible to reduce the number of man-hours for inputting or changing the rank or conversion file, and to efficiently grasp the number of flows, the cumulative number of machining, and the tact time using a computer, etc., and to predict the operating rate of the entire production line in advance. And the operation rate of the entire line is improved, and as a result, the efficiency of production management is improved.

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

2 to 12 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 a total of 6 communication terminals. Reference numerals 4A to 4X denote sequencers (processing execution means) of the terminal, which are configured by a welding robot or the like that executes welding processing. Reference numeral 5 denotes a production line, which places each body (workpiece) 6 including a different model on a transporting trolley (not shown) and transports it by a predetermined number in a predetermined order from a loading section to a sending 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 processes the processing information for each line. Distribute files to aggregate the files. 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 the information of the processing content is distributed through the network 3A.

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 via a personal computer network 3A to 2E, which is one of the derivative centralized maintenance computers, in a constantly communicating state to back up the data.
That is, 2E, which is one of the derivative aggregation maintenance computers, stores data at the same level as the host computer 1 which is a file server as a data storage function, and has an alternative function. Further, the derivative aggregation maintenance computers 2C, 2D, and 2E create a conversion file for classifying the processing order information into a model derivation section for each processing step of the production line 5, and store the conversion file in the host computer 1.
Distribute to 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 centralized maintenance computers which are always in communication. That is, the host computer 1 stores data as a function of a file server, and 2E, one of the derivative centralized maintenance computers, stores data of the host computer 1 at the same level as an alternative function. Further, 2C and 2D of the derivative aggregation maintenance computers 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.

In other words, of the derivative aggregation maintenance computer
2C and 2D replace the line area computers 2A and 2B, and satisfy the function as the line area computer after the processing order information is distributed from the host computer 1. 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, 2D, 2E is stored once in the host computer 1 and then input to the line area computers 2A, 2B via the network 3A. These computers receive the processing order information from the host computer 1 and the conversion file, convert the processing order information into processing instruction information for each processing step based on the conversion file, and aggregates the information to obtain different models for each body 6. Processing instructions corresponding to each processing content are output to the sequencers 4A to 4X for each line. Line area computer
2C is a disk drive 21 and a printer as accessories
22, a keyboard 23 and a CRT display 24. The same applies to the other derivative centralized maintenance computers 2D and the line area computers 2A and 2B (others are not shown). Reference numeral 25 denotes a transceiver of the personal computer network 3A, and the 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.

31-35 are performance monitoring computers, network 3
, The process status of each process is received. The data of the process status is measured by the sequencers 4A to 4X performing a predetermined welding process. Tact equivalent to the total number of machining and machining time per unit, and sequencers 4A to 4X
The status monitor computer receives the status signal of automatic / manual, cutting and change signals, and the remaining number of machines which are updated each time a predetermined welding process is completed. In addition, using the calculation result of the total number of machines processed in the own process and the total number of machines processed in the next process as the number of flows of a specific line from the process status data, the data including at least the number of flows is networked. 3 to each process. These performance monitoring computers are located in, for example, offices, maintenance departments, planning rooms, warehouses, etc.
Collect, analyze, distribute and display machining results in real time. 36 is a performance data collection controller, which collects and distributes processing results in real time. The performance monitor computer 31 has a main body 41, a printer 42, a keyboard 43, and a CRT display 44, and the same applies to other performance monitor computers (however, other symbols are omitted). 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. With this information, the processing order is set and complemented for each body 6 on the production line 5 for each model, every derivative, etc. for each predetermined number. This information is distributed to the line area computers 2A and 2B via the network 3. The information includes, for example, the model of the body 6 (the model name of the body and the 4-door, 2-door, etc.), derivative information (destination country, destination: cold district, etc.), and optional information (whether the sunroof is present or not). Etc.) are also included. These correspond to, for example, model-specific derived aggregate codes for each line.

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 information from the host computer 1 is analyzed by the line area computers 2A and 2B based on the conversion file, and processing instructions for each body 6 for different models are output to the sequencers 4A to 4X for each line. On the other hand, on the production line 5, each body 6 including different models is placed on a transport trolley from the input section to the output section, and is transported every predetermined number in a predetermined order. Then, based on the processing instruction for each line, the sequencers 4A to 4X apply a predetermined number of each body 6 placed on the production line 5 to each body 6 in the arranged order.
A predetermined welding process corresponding to each derivation is performed for each line.

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 were 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, and 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 hood 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, a black portion is a portion where welding is automatically performed, and a hatched portion is a portion where welding is performed manually. In addition, the white portions are portions where the jig replacement (CH) according to the model change is performed.

Here, in the distribution of the next process status and the number of processing flows using the network 3, for example, setting of a next process node number and a name, data reception from the next process, and the like are performed. As a specific example of such a processing situation, for example, the number of flows between lines is shown as in FIG. In the measurement of the number of machines and the tact corresponding to the machining time per unit in the M / C machining, setting of the number of machines, setting of the tact measurement, storage of the number of machines and tact measurement data, and the like are performed. In the setting of the number of units, you can select the M / C operation mode (manual / automatic change), whether or not the number of units can be counted depending on the presence or absence of a work,
Select the machining time measurement timing in one M / C cycle. The measurement of the tact is basically the same as the processing number count timing, and the measurement and data storage of the number of machines and the tact are data communication that can be communicated on the network 3 (for example, writing to a register circuit). In the calculation of the number of units in the processing order data, each time one unit is processed, it is stored as the number of remaining units in the processing lot.
The number of machines processed on a day is stored as cumulative number data. The deletion of the cumulative number is automatically performed at the beginning of the day.

As a specific example of such a processing situation, for example, the remaining number of processing lots is shown in FIG.
The actual number of machines processed is shown in FIG. in this case,
On the display, a general integrated screen shown in FIG. 8 is normally displayed. When "roof" is designated on the screen, a detailed screen shown in FIG. 9 is displayed. The tact data is shown in FIGS. 10 and 11, which represent the first floor line and the second floor line, respectively, for a total of two screens. In the figure, the black and white inverted data indicates the latest data,
Each time the inverted data changes, the average value is calculated and displayed.

Furthermore, the measured value of the process tact by line is
It is shown as in Figure 12. In FIG. 12, each column is the first,
2 shows the time histories, and the tact result is shown in the order of the numbers. As an example, the required processing time of the first, fifth and fourteenth machines is picked up in the figure.

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

(I) The processing order data and the conversion file for the body 6 are collectively managed by the host computer 1 as the upper controller, and the line area computers 2A and 2B as the lower controllers analyze the processing order data based on the conversion file. , Consolidation and processing execution means f
Are distributed by the sequencers 4A to 4X, and after the processing is executed by the production line b, the processing status and the result are measured and stored by the sequencers 4A to 4X as the processing execution means f, and are recorded by the performance monitor controller g. Since the process status and the flow number between the own process and the next process are obtained by a certain performance monitor computer 31 to 35, and the distribution and display are performed using data including at least the flow number,
It is possible to reduce man-hours for input and conversion file analysis or change processing order analysis and consolidation, which is different from operator analysis and consolidation every time as before, and to efficiently calculate the number of flows. For example, the operation rate of the entire production line can be predicted in advance, the operation rate of the entire line can be improved, and as a result, the efficiency of production management can be improved. As a result, it is possible to realize an efficient automated line system.

Specifically, it is possible to predict in advance the non-operation of the entire line due to the shortage of the number of flows, and also to predict the non-operation of the own process due to the excess of the number of flows in advance. Can be improved.

(II) Also, in this embodiment, the number of machining operations in the M / C machining and the tact corresponding to the machining time per unit are measured, and the machining information is distributed using a network. Thus, the efficiency of the processing can be improved, and the reliability of the data can be enhanced by the unification of the data, so that it can be economical.

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.

A part of the functions of the performance monitoring computer may be assigned to the performance data collection controller in accordance with the processing capacity of the computer.

[Effects] According to the present invention, conversion data in which processing order data and conversion files for a workpiece are collectively managed by a higher-level controller, and classified into a model-derived section for each processing step of a production line by a middle-level controller. Create a file and analyze and collect the rank data based on the conversion file by the lower-level controller, and use the performance monitor computer to use data including at least the next process status and the number of machining flows between the own process and the next process. As a result, the number of man-hours can be reduced, and the number of flows can be ascertained efficiently using a computer, etc., and the operating rate of the entire production line can be predicted in advance, and the operating rate of the entire line can be estimated. Can be improved. As a result, a highly efficient automated line system can be constructed, and the efficiency of production management can be increased. In addition, by measuring the number of machining operations and the tact equivalent to the machining time per unit in M / C machining, and distributing such machining information using a network, the efficiency of machining can be improved from this aspect as well. And the reliability of the data can be improved by the unification of the data, and the economic efficiency can be improved.

[Brief description of the drawings]

Fig. 1 is a basic conceptual diagram of the present invention, Figs. 2 to 12 are diagrams showing an embodiment of a production management system according to the present invention, and Fig. 2 is a schematic diagram 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. 6 is a diagram showing a specific example of the number of flows between lines, FIG. 7 is a diagram showing the number of remaining machining lots, FIG. 8 is a diagram showing a list of the number of accumulated machining units, and FIG. Fig. 10 shows the measured values of the first floor line process tact, Fig. 11 shows the measured values of the second floor line process tact, and Fig. 12 shows the measured values of the process tact. Fig. 13 shows the processing order of the conventional production management system. FIG. 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 (3)

(57) [Claims] 1. A plurality of production lines 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 for a workpiece on the production line, For each model,
Creates a higher-level controller that sets and stores the processing contents for each derivation and distributes processing information through the network, and creates a conversion file that divides the information on the processing order into model-derived sections for each processing step of the production line. Receiving a conversion file from the middle controller for delivering the conversion file to the upper controller, processing information from the upper controller, and processing the processing information for each processing step based on the conversion file. A lower-level controller that converts the information into instruction information, aggregates and provides a processing instruction, and is arranged in each area of a plurality of production lines, and a predetermined number of workpieces are arranged based on the processing instruction from the lower-level controller. Processing execution means for executing predetermined processing corresponding to each model derivation in the processing order and for each line; A performance monitor controller that communicates data through the network, obtains the status of the next process and the number of machining flows between the own process and the next process, and distributes the process information through a network using data including at least the number of flows. And a production management system comprising: 2. The actual performance monitor controller according to the present invention, as a process actual condition, a signal of a jig change accompanying automatic / manual switching, cutting, model switching, a total number of units, and a tact corresponding to a machining time per unit number in each process. 2. The production management system according to claim 1, wherein the information is received from a line. 3. The result monitor controller calculates, as a flow number of machining between the own process and the next process, a calculation result of the total number of machines finished in the own process and the total number of machines finished in the next process. The production management system according to claim 1, wherein the system is used.