JP3055656B2 - Automatic creation of machining plan - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for automatically creating a machining plan for instructing a work input sequence and a loading time based on a production plan for an entire factory.

[0002]

2. Description of the Related Art Production plants for automobiles and the like are provided with a body welding line that supplies sheet metal parts and the like to form a body and the like by welding and the like, a painting processing line that paints a body and the like assembled by the body welding line, and a paint processing line. It is equipped with a body assembly line, etc., which assembles various parts to a completed body to complete the vehicle. Conveyors are arranged on each line, and the workpieces flow through the body welding line, the painting processing line, and the body assembly line to produce completed vehicles.

[0003] However, when a plurality of types of workpieces are flowed on a single production line in order to cope with many types of products due to diversification of products, there are many branch points and junction points on the conveyor of each line. , Each conveyor must be controlled individually. In particular, the painting line is generally composed of one line for equipment reasons. Therefore, a processing plan that instructs the size of the lot of the work to be flown on each line, the flow order, and the like greatly affects the line operation rate. Therefore, as a conventional method of creating a machining plan,
It is known that a worker (operator) creates a daily machining plan for each line based on his / her own rules of thumb based on a completed vehicle production plan, which is a production plan for the entire factory, which is automatically created by a factory host computer. Have been.

[0004]

In the conventional method of creating a machining plan, since the operator (operator) creates the machining plan based on his own empirical rules and the like, for example, in a painting machining line, the painting work is delayed or the color is lost due to a plan creation error. There is a problem that a difference or the like occurs, which causes a reduction in the line operation rate. In addition, it takes time to train the planning staff,
There is a problem that the planning accuracy varies depending on the operator (operator) who plans.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems of the prior art, and an object of the present invention is to eliminate a human error in a machining plan and to improve a line operation rate. It is intended to provide a method for automatically creating a processing plan.

[0006]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides a method of supplying a material, a coating process, and an assembling process in this order.
A method of creating a processing plan for a production line that produces a wide variety of products by flowing a product, wherein the assembling process based on the production plan is performed.
The assembly process based on the product delivery time (T2)
The time required for the assembly process is calculated using the maximum assembly tact time among the assembly tact times of
The work delivery time from the painting process to the assembly process (T
1) is calculated, and then the work delivery time to the assembling process is calculated.
(T1) and the basic precedence time (T3) for each part required in the coating step, from the material supply step to the above-mentioned step.
Calculate the work input time (T4) to the painting process , and then
Work input sequence and work input time to the painting process
A processing plan instructing (T4) is automatically created.

[0007]

Embodiments of the present invention will be described below with reference to the accompanying drawings. Here, FIG. 1 is a configuration diagram of a motorcycle production line to which the method for automatically creating a machining plan according to the present invention is applied, FIG. 2 is a configuration diagram of a production management system, and FIG.
Is a configuration diagram of a communication system that constitutes a production management system,
FIG. 4 is an explanatory diagram of a flow of a method for automatically creating a machining plan according to the present invention, and FIG. 5 is an explanatory diagram of a data flow of a production management system.

A motorcycle production line to which the method for automatically creating a machining plan according to the present invention is applied, as shown in FIG.
The system includes a material supply line 1, a painting processing line 2, a painted finished product supply line 3, and a vehicle body assembly line 4. Each of the lines 1, 2, 3, and 4 is connected by a conveyor 5.

The material supply line 1 includes a conveyor 5 having a branch point and a junction, and has two loop lines L1, L2.
2 and six main lines A, B, C... F, and one sub line G. Also, main line A,
B and D are provided with bypass lines a, b and d, respectively. In the material supply line 1, a material forming a frame or the like corresponding to the type of the motorcycle is supplied to each of the lines A, B, C,... F by hanging it on a hanger (HG) as a material transport carrier. The material is hung and hung on a hanger and assembled by welding or the like to form a desired frame or component. Then, the branched conveyors 5 are merged into one line, and the assembled frames and parts are carried into the painting processing line 2 which is a post-process.

The coating line 2 comprises a single main line in which processes such as pretreatment, electrodeposition, drying oven, coating booth, finishing oven, inspection and grounding are connected by a conveyor 5. The coating line 2 is provided with a conveyor 5 that bypasses the electrodeposition process and reaches a drying furnace, and a conveyor 5 that bypasses a coating booth and a finishing furnace and reaches an inspection and grounding process. In the coating processing line 2, processes such as pre-processing, electrodeposition, drying oven, painting booth, finishing oven, inspection and grounding, etc. are performed on the frames and parts carried from the material supply line 1 by hanging them on hangers. The frames and parts that have been subjected to the coating process are carried into the finished product supply line 3.

[0011] In the finished paint supply line 3, small parts are assembled in a tank or the like that has been subjected to a painting process. Also,
The finished paint supply line 3 also manufactures knockdown parts and service parts (replenishment parts). Further, a frame, parts, knockdown parts, and the like are assembled on a vehicle assembly line 4 including a plurality of lines (for example, six lines from a first line to a sixth line) in order to complete the motorcycle.
Transported to

In the vehicle body assembly line 4, the assembly conveyor of each line is driven at an assembly tact time determined by a model flowing in each line (first line to sixth line).
Various parts are assembled into a completed vehicle and paid out at a predetermined time based on a production plan.

[0013] Such a motorcycle production line includes:
As shown in FIG. 2, a computer network 6 as a communication network and a sequencer network 7 are provided in the material supply line 1, the coating processing line 2, and the finished coating product supply line 3 to form a production management system. Note that the sequencer network 7 is provided in each of the two areas.

The computer network 6 includes a personal computer for planning (planning personal computer) 1
0, database management personal computer (data management personal computer) 11, conveyor control personal computer (conveyor control personal computer) 12, material input personal computer (material input personal computer) 13, process terminal personal computer (process personal computer) 1
4. An inspection terminal personal computer (inspection result input personal computer) 15 and an area sequencer (programmable controller) 16 are connected.

Material input personal computer 13
Are the two loop lines L1 and L2 of the material supply line 1.
And a total of seven units are installed in one sublane G. Furthermore, a personal computer 1 for creating a plan
0 is connected to a factory host computer 17 constituting the host system via a gateway 18 as an interface. The factory host computer 1
If it is possible to connect the computer 7 directly to the computer network 6, the gateway 18 can be omitted.

Also, two sequencer networks 7,
7 includes an area sequencer 16, a panel control panel 19 disposed in each step for controlling the conveyor 5, and a conveyor operation monitor 20 for displaying an abnormality and an abnormality history of the conveyor 5.
Is connected. The panel control panel 19 is composed of a sequencer (programmable controller) or the like, and is installed corresponding to the conveyor 5 divided in a predetermined range.

Therefore, the computer network 6 and the sequencer networks 7, 7 are connected via the area sequencers 16, 16 as interfaces. The interface between the computer network 6 and the sequencer network 7 may be configured using a personal computer instead of a programmable controller. Reference numeral 25 denotes a management setting panel.

Personal computer 10 for creating a plan
Creates a daily execution machining plan file based on a monthly order file (such as a production order or a parts development list) stored in the factory host computer 17 and transmits it to the conveyor control personal computer 12. The conveyor control personal computer 12 creates production plan information, material input data, apparatus empty instruction information, merge instruction information, and the like based on the daily execution machining plan file.

Conveyor control personal computer 1
2 transmits the production plan information to the personal computer 14 for the process terminal and the personal computer 15 for the inspection terminal, transmits the data for material input to the personal computer 13 for material input, and conveys the information such as the equipment empty instruction information and the merge instruction information. The control information is transmitted to the area sequencer 16. In addition, the conveyor control personal computer 1
2 transmits information necessary for the painting operation to the automatic painting machine.

The process terminal personal computer 14 installed in each process displays the production order based on the production plan information. Inspection terminal personal computer 15
Displays the production order based on the production plan information, inputs the inspection result, and transmits the inspection result to the personal computer 12 for conveyor control. Material input personal computer 13 installed in the hanger hanging process
Displays hanger hanging information (line conveyor operation information) based on the material input data and transmits it to the ID tag 21.

The area sequencer 16 receives hanger information indicating how to flow hangers (order) based on conveyor control information such as apparatus emptying instruction information and merging instruction information, and transmits this hanger information to each panel control panel 19. I do. Each panel control panel 19 processes branching or merging instruction information based on hanger information, and controls the operation of the conveyor 5 in each process according to the branching or merging instruction information.

The ID tag 21 is detachably attached to the hanger which is moved by the conveyor 5 of each of the lines 1, 2 and 3. The ID tag 21 receives and stores a lot number (Lot-No), branch data, and the like as line conveyor operation information from the material input personal computer 13 and stores the panel control panel 19 at a branch point or a junction of the conveyor 5. The hanger number (HG-No) and the lot number (Lot-N)
o), transmitting branch data, passage time, and the like.

As shown in FIG. 3, an ID system 22 as a communication system in which the personal computer 13 for material input, the panel control panel 19, and the ID tag 21 communicate with each other,
An ID controller 23 connected to each of the material input personal computer 13 and the panel control panel 19;
It comprises an ID antenna 24 connected to a D controller 23.

The ID controller 23 connected to the material input personal computer 13 transmits the line conveyor operation information from the material input personal computer 13 to the ID tag 21 via the ID antenna 24. The ID controller 2 connected to the panel control panel 19
3 receives the passage result information from the ID tag 21 via the ID antenna 24 and inputs the information to the panel control panel 19. In addition, the ID antenna 24 is installed at a branch point or a junction of the conveyor 5 which mainly becomes a passage point of the work.

A method of automatically creating a processing plan applied to the coating processing line 2 in the production management system configured as described above will be described. First, as shown in FIG. 4, the plan creating personal computer 10 stores a monthly order file (completed vehicle) for each line (first line to sixth line) of the vehicle body assembly line 4 previously input to the factory host computer 17. The in-process database (model name, destination, and part number of the drawing) stored in the database management personal computer 11 based on the production order and the required quantity development list which is a component list based on the model. The parts to be painted are selected with reference to the basic part numbers, etc., and the paint color and the number to be put on the hanger, which are data specific to painting, are set.
A monthly painting process file for instructing the production order and the like is created on the (line to sixth line) (step S1).

Next, the personal computer 10 for preparing a plan is connected to the personal computer 1 for database management for each vehicle body assembly line (first line to sixth line).
Based on the lot division conditions stored in step 1, it is determined which lot size is the best to flow the parts as the object to be coated to the coating processing line 2, and the lot division processing is performed in the order of production order. Is performed (step S2). For equipment reasons, it is generally more convenient to make the lot size in the painting line 2 smaller than the lot size in the body assembly line 4.

Further, as shown in FIG. 2, the personal computer 10 for preparing a plan pays out the finished product supply line at the number of lots divided according to the production order for each body assembly line (first line to sixth line). T1 is calculated in consideration of the maximum assembly tact time based on the vehicle assembly line payout time T2, which is the time at which the completed vehicle given from the factory host computer 17 turns off the vehicle assembly line 4 (step S3). If the maximum assembly tact time is not taken into consideration, there is a possibility that some models may not be completely assembled on the vehicle body assembly line 4. The maximum assembly tact time refers to the longest tact time among various types of assembly tact times actually flowing on the vehicle body assembly line 4 at a predetermined lot size.

Next, as shown in FIG. 2, the personal computer 10 for preparing a plan uses the basic precedents in the painting processing line 2 and the painted finished product supply line 3 which are different for each part stored in the personal computer 11 for database management. Based on the degree time T3, a paint processing line input time (pre-processing input time) T4 at which a work such as a frame is carried into the coating processing line 2 from the material supply line 1 from the coating finished product supply line supply time T1 is calculated. (Step S
4). That is, this is because the time obtained by subtracting the basic precedence time T3 from the finished paint product supply line payout time T1 and going back is the paint processing line input time T4. In addition, painting processing line 2
And the basic precedence time T3 in the finished paint supply line 3 is the time required from the pretreatment to the delivery of the finished paint supply line through a drying furnace, etc. Since there are parts that do not fit in the table, they differ depending on the type of parts.

Further, the planning personal computer 10 performs daily processing on the coating processing line input time T4 calculated in consideration of the basic precedence time T3, and determines the coating order and the input time, etc. A primary processing plan is created and used as a daily primary processing plan file (step S5). In addition, the daily process is a calculation process in which a painting processing line input time T4 obtained by subtracting a necessary time from the vehicle body assembly line payout time T2 is specifically set to a month, a day, a hour, a minute, and a second. Say.

Further, KD / K / D of knockdown parts and service parts which are not included in the monthly order file for each line (first line to sixth line) of the vehicle body assembly line 4 which is input to the factory host computer 17 in advance. SP
As for the parts, a worker (operator) inputs a monthly production plan for the KD / SP parts to the personal computer 10 for preparing a plan, and prepares a KD / SP processing plan file (step S6).

Then, the planning personal computer 10 prepares a painting processing plan (secondary processing plan) for all the painted parts on a time basis based on the primary processing plan file and the KD / SP processing plan file. A second daily machining plan file is set (step S7). Further, the worker (operator) confirms and corrects the secondary daily machining plan using the personal computer 10 for creating a plan, saves the file as a secondary daily execution machining plan (step S).
8). In addition, the secondary daily execution machining plan file is basically stored one month earlier. Here, the in-process database is managed by installing the database management personal computer 11, but the function can be incorporated in the plan creation personal computer 10.

The secondary daily execution processing plan file created by the personal computer 10 for creating a plan in this way is also created for the material supply line 1 other than the coating processing line 2 and the like. Then, as shown in FIG. 5, production management based on the automatically created machining plan is executed as follows. The second daily execution processing plan is transmitted to the conveyor control personal computer 12 via the computer network 6. Then, the conveyor control personal computer 12 creates conveyor control information such as production plan information, material input data, apparatus emptying instruction information, and merging instruction information based on the secondary daily execution machining plan.

Next, the conveyor control personal computer 12 transmits the production plan information to the process terminal personal computer 14 and the inspection terminal personal computer 15 via the computer network 6 and the material input data (for one day) to each material. Conveyor control information such as apparatus emptying instruction information and merging instruction information is transmitted to the input personal computer 13 to the area sequencer 16.

Then, the process terminal personal computer 14 and the inspection terminal personal computer 15 display the production order based on the production plan information. The material input personal computer 13 displays hanger hanging information (line conveyor operation information) based on the material input data. The area sequencer 16 processes hanger information based on conveyor control information such as apparatus empty instruction information and merging instruction information, and transmits this hanger information to each panel control panel 19.

Further, when the line conveyor operation information is displayed on each material input personal computer 13, the operator hangs a material suitable for the displayed line conveyor operation information on a hanger and inserts the material into the conveyor 5. Then, at the time of dispensing the hanger, the ID controller 23 and the ID antenna 2
The line conveyor operation information is automatically written into the ID tag 21 attached to the hanger via the line 4.

Each panel control panel 19 processes branching or merging instruction information based on hanger information, and controls the operation of the conveyor 5 in each process according to the branching or merging instruction information. The hanger with the material suspended is transported by the conveyor 5 to the next step. At the branch point, the panel control panel 19 reads the branch destination from the line conveyor operation information written in the ID tag 21 via the ID system 22, and the hanger is automatically branched to the desired conveyor 5. At the junction, the hangers are automatically controlled in a predetermined order according to the merge priority instruction information transmitted to the panel control panel 19 from the conveyor control personal computer 12 via the area sequencer 16 and the sequencer network 7. Conveyer 5.

Passing information (hanger number, lot number, branch data, hanger passing time, etc.) at each branch point and junction (place where the ID antenna 24 is installed) is stored in the ID system 22, panel control panel 19, area sequencer 16 Is transmitted to the conveyor control personal computer 12 via the.

When the inspection result is input by the inspection terminal personal computer 15, the inspection result information is transmitted to the conveyor control personal computer 12. Then, the conveyor control personal computer 12 collects various result information such as passage result information and inspection result information, and transmits the various result information to the plan creation personal computer 10. Further, the plan creating personal computer 10 creates lot-based production result information based on various result information, and transmits the lot-based production result information to the factory host computer 17.

Further, the conveyor control personal computer 12 transmits the lot number which has been carried into the coating processing line 2 to the coating personal computer in the coating booth.
Then, the painting robot performs the painting operation based on the painting information from the painting personal computer based on the transmitted lot number.

At the time of dispensing from the finished painted product supply line 3 to the vehicle body assembly line 4, hanger alignment control is performed in order to perform the minimum unit payout for each component, and the next step of the vehicle assembly line 4 is performed.
Carry in. For example, 8 small parts on one hanger,
Four tanks are hung on two hangers, and two frames are hung on four hangers. A total of seven hangers are aligned and carried into the vehicle assembly line 4 in the next process.

As for the abnormal stop information of the conveyor 5, the stop location, the stop time, the stop reason, and the like are described in the ID system 22,
The data is transmitted to the conveyor control personal computer 12 via the panel control panel 19 and the area sequencer 16, and the result collection processing is performed by the conveyor control personal computer 12. Therefore, various performance data is automatically collected in real time.

[0042]

As described above, according to the present invention, the machining plan for each process, which is the basis of production management, is automatically created based on the production plan for the entire factory. Man-hours are greatly reduced. Further, since the machining plan is created without depending on the skill of the operator (operator), the accuracy of the machining plan is also stabilized. Further, human errors, such as missing a plan or forgetting to input, are eliminated when creating a machining plan, so that the line operation rate can be improved.

[Brief description of the drawings]

FIG. 1 is a configuration diagram of a motorcycle production line.

FIG. 2 is a configuration diagram of a production management system in a motorcycle production line.

FIG. 3 is a configuration diagram of a communication system configuring a production management system;

FIG. 4 is a flowchart illustrating a method for automatically creating a machining plan according to the present invention.

FIG. 5 is an explanatory diagram of a data flow of the production management system.

[Explanation of symbols]

1: Material supply line, 2: Paint processing line, 3: Painted finished product supply line, 4: Body assembly line, 5: Conveyor,
6 computer network, 7 sequencer network, 10 personal computer for planning, 1
DESCRIPTION OF SYMBOLS 1 ... Data management personal computer, 12 ... Conveyor control personal computer, 13 ... Material input personal computer, 16 ... Area sequencer, 1
9: panel control panel, 21: ID tag, 22: ID system, 23: ID controller, 24: ID antenna (antenna), T1: paint processing line payout time, T2: body assembly line payout time, T3: paint processing line The basic precedence time in the above, T4 ... time of inputting the coating processing line.

Continuing on the front page (72) Inventor, Shozo Ueda 1500, Hirakawa, Otsu-cho, Kikuchi-gun, Kumamoto Prefecture Inside of Honda Motor Co., Ltd.Kumamoto Works (72) (56) References JP-A-8-309646 (JP, A) JP-A-4-348856 (JP, A) JP-A-2-59259 (JP, A) (58) Fields investigated (Int. ⁷ , DB name) G05B 19/418

Claims (1)

(57) [Claims] 1. An order of a material supply process, a coating process, and an assembly process.
Wherein a method of making a working planning production line for producing many kinds of products flowing the work, based on the production plan in
The assembling process is performed based on the product delivery time (T2) in the assembling process.
Calculate the time required for the assembly process using the maximum assembly tact time among the assembly tact times of a plurality of products flowing through
And the work delivery time from the painting process to the assembly process
(T1) is calculated, and then the work is paid out to the assembly process.
Time (T1) and parts required in the painting process
From the material supply process using the basic precedence time (T3) for each
Calculating a work piece introducing time (T4) to said coating step, following
In addition, a method of automatically creating a work plan, which automatically creates a work plan instructing a work input sequence and a work input time (T4) in the coating process .