JP3945213B2 - Process inventory management method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a process inventory management method.
[0002]
[Prior art]
In the factory production line, it is impossible to place all the parts necessary for one day production near the line, so parts are delivered to each process of the line when the number of parts is reduced to some extent.
[0003]
In order to deliver parts to the production line, it is necessary to grasp which parts are insufficient in which process. Therefore, conventionally, a “kanban” corresponding to a part for each process or a box containing a part is used as an “empty box kanban”, and the parts are delivered to each process based on the Kanban. Kanbans are made of paper or plastic, and indicate the part number, part name, required number, required process, manufacturer, etc. of the part. Similarly, an empty box kanban is labeled with the product number, product name, number, and the like.
[0004]
FIG. 7 is an explanatory diagram of a conventional Kanban type part delivery method. The in-process kanban 11 or empty box kanban 12 (hereinafter collectively referred to as the kanban 11) provided for each process is collected at a collection post (not shown) on the line, and from the collection post to the kanban collection / delivery room. Collected in thirteen.
[0005]
The computer 14 in the kanban collection / delivery room 13 receives the production instruction (the type of product to be produced, the production quantity, the production order, etc.) from the host computer 15. In addition, the operator confirms the contents of the collected kanban 11 and inputs the parts that need to be delivered to the computer 14. Then, based on the production instruction from the host computer 15 and the parts specified by the kanban 11, the computer 14 instructs the warehouse to issue the parts.
[0006]
When a part is delivered from the warehouse, the local transport vehicle transports the part to the parts storage 16. Then, the parts transporter 17 delivers the parts to the shelves of the corresponding process in the line.
[0007]
[Problems to be solved by the invention]
In the parts delivery method using the conventional kanban 11 described above, the kanban 11 is collected in the kanban collection / delivery room 13 so that only the quantity of parts corresponding to the kanban 11 can be known. I couldn't figure it out.
[0008]
Furthermore, the kanban 11 is used for the residence time when the kanban 11 collected from the line process stays in the collection post, the kanban collection / delivery room 13, the parts pick-up instruction and the warehouse delivery instruction. It takes a long time to move the product to the target location, and it takes time to actually deliver the parts to each process from the parts delivery request, so each process must have extra parts inventory There was also a problem.
[0009]
As a method of checking the inventory of parts in a process, it is conceivable that an operator checks the inventory of each process, but this method is labor intensive and is not an efficient method.
As another method, it is conceivable to install a barcode reader in each process, and to grasp the quantity of parts used in the process by reading the barcode recorded in the parts.
[0010]
However, this method requires the operator to read the barcode, and the parts must be aligned so that the barcode can be read from the parts placed in the parts box in different directions. The problem that the burden of the increase increases.
[0011]
For example, Japanese Patent Laid-Open No. 8-12026 is known as a known technique for manufacturing management. This publication describes a method for carrying materials, manufacturing instructions, and inventory management in a factory for manufacturing steel sheets by a small number of people or unattended. However, the present invention is merely one feature in that the order of each manufacturing process flow of the steel material is arranged according to the order information so that a production plan for the entire manufacturing process can be made. This relates to the manufacturing process of one part called a band.
[0012]
An object of the present invention is to make it possible to more accurately grasp the inventory of process parts.
[0013]
[Means for Solving the Problems]
The process inventory control method according to the present invention includes a part used for the finished product and the rejected product based on information for identifying the product and information on the rejected product determined to be rejected in the inspection process, and the component. Each part used for the finished product and the rejected product based on the quantity of the finished product and the rejected product and the quantity of the parts used for the finished product and the rejected product. And the inventory quantity of the parts in each process is calculated based on the used quantity of each part and information on the parts delivered to each process.
[0014]
According to the present invention, the parts used in the finished product and the inspection-failed product and the quantity of the parts can be acquired, and therefore the inventory quantity of the parts in each process can be grasped more accurately from the information. Can do.
[0015]
In the process inventory management method of the above invention, the quantity of parts to be delivered to each process is calculated based on the inventory quantity of the parts in each process and the information related to the parts delivered to each process, and the delivery destination process is indicated. The information and the quantity of parts to be delivered are displayed on the display device of the parts carrier.
[0016]
According to the present invention, since the inventory quantity of parts in each process can be grasped in real time, it is possible to instruct the parts transporter to deliver the parts so that there is no missing part in each process. In addition, information on the delivery destination process and the parts to be delivered (for example, the part name and quantity) is displayed on the display device of the parts transport vehicle, and the driver of the parts transport vehicle sees the display and displays the parts to each process. Since delivery can be performed, the efficiency of delivery work can be improved.
[0017]
In the inventory management method for the process of the above invention, the step of obtaining information indicating whether or not the parts transporter has stopped at the delivery destination process for delivering the part, and calculating the inventory quantity of the part in each process If the acquired information indicates that the parts carrier has stopped at the delivery destination process, the used quantity of each part used for the finished product and the rejected product and the delivery destination process Based on the information on the delivered parts, the inventory quantity of the parts in the process is calculated.
[0018]
By configuring in this way, for example, it is possible to determine whether or not a part has been replenished in the process by acquiring information indicating the process where the parts transport vehicle has stopped for loading or unloading the part or the position thereof. it can. Therefore, it is possible to more accurately grasp the inventory of parts in each process based on the determination result.
[0019]
In the above invention, information specifying a product and information specifying a part used for the product are stored in association with each other, and when the information specifying the product is acquired, the information is stored in association with the information. It is also possible to develop the information at the component level by acquiring information for identifying the component used in the product.
[0022]
In the above invention, the information related to the parts delivered to each process includes information for designating the parts and the quantity of the parts.
[0023]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is an explanatory diagram of an inventory management method for processes according to the first embodiment of this invention.
[0024]
In the process of inspecting the finished product in the production line 21, a barcode reader 22 is installed. Each product is attached with a barcode specifying the product printed on a label or the like, and the barcode reader 22 reads the barcode of the product. The barcode read by the barcode reader 22 is transmitted to the production instruction computer 23 as information for specifying product specifications.
[0025]
When the production instruction computer 23 obtains the barcode of the finished product from the barcode reader 22, the production instruction computer 23 develops the barcode into component level information. For example, the production instruction computer 23 stores a plurality of barcodes for identifying products in association with data indicating the configuration of parts used in each product in a storage device such as a hard disk, and the obtained barcodes The data indicating the part configuration of the product corresponding to is read out from the storage device to be developed into part level information. Further, the production instruction computer 23 identifies a product by the bar code output from the bar code reader 22, and develops it into part level information indicating the parts used in the product and the used quantity of each part. Further, the production quantity is counted by a counter provided on the production line or a barcode output from the barcode reader 22.
[0026]
The production instruction computer 32 calculates the total of the used quantity of each part used for the product from the used quantity and the production quantity of the parts used for one product, and the cumulative used quantity and the host computer 15 Based on the production instruction (the type of product to be produced, production quantity, production order, etc.), the inventory management computer 25 is instructed to issue the part from the parts storage 24.
[0027]
The production instruction computer 23 instructs the parts transport vehicle 26 to transport parts to each process, and stores the contents of the parts delivery instruction to each process instructed to the parts transport vehicle 26.
[0028]
Further, the production instruction computer 23 calculates the inventory quantity of parts in each process based on the quantity of parts used for the production quantity of the product and the quantity of each part delivered to each process by the parts transport vehicle 26. It is assumed that the parts used in each process are known in advance.
[0029]
FIG. 2 is an explanatory diagram of wireless communication of the parts transport vehicle 26. A wireless repeater 32 is installed on the ceiling of the factory. The wireless signal transmitted from the parts transport vehicle 26 is relayed and transmitted to the antenna 33 of the house 31. The antenna 33 is connected to the production instruction computer 23, and the production instruction data from the production instruction computer 23 is transmitted from the antenna 33 converted into a radio signal to each component carrier 26 via the repeater 32. . A radio signal transmitted from the parts transport vehicle 26 is relayed by the repeater 32 and received by the antenna 33. Furthermore, radio signals can be transmitted and received between the parts transport vehicles 26.
[0030]
When receiving a delivery instruction wirelessly from the production instruction computer 23, the parts transport vehicle 26 displays the delivery instruction content on the display device. The driver looks at the contents of the delivery instruction displayed on the display device of the parts carrier 26 and delivers the parts to the corresponding process.
[0031]
The parts transport vehicle 26 has a position detection function. When the parts are delivered to the instructed process, the part transport car 26 detects which process on the production line 21 has stopped, and the detected position is wirelessly produced by a production instruction computer. 23.
[0032]
FIG. 3 is a diagram showing a position where the parts transport vehicle 26 stops for unloading. A process indicated by a black circle in FIG. 3 is a process in which the vehicle stops to replenish parts, and the parts transport vehicle 26 transmits the position information or information indicating the process to the production instruction computer 23 by radio.
[0033]
Here, the processing of the production instruction computer 23 of the inventory management system of the first embodiment will be described with reference to the flowchart of FIG. In the flowchart of FIG. 4, operations performed by other than the production instruction computer 23 are also described.
[0034]
The barcode of the finished product is read by the barcode reader 22 (FIG. 4, S11). The production instruction computer 23 receives the barcode read by the barcode reader 22, and develops it into component level information based on the barcode (S12). In this process, it is determined from the product barcode which parts were used, how many and when they were used, and the number of parts used in one product was accumulated for the number of units produced. The cumulative value (hereinafter simply referred to as the used quantity) is calculated.
[0035]
In addition, the production instruction computer 23 determines which process based on the quantity of parts used in the production plan and production line, the process of the delivery destination of parts to the parts transport vehicle 26, the type of parts to be delivered, and the quantity of parts used. Then, the parts carrier 26 is instructed wirelessly which parts, how many and when to deliver them (S13). Since the parts delivery instruction is displayed on the display device of the parts carrier 26, the driver loads the parts according to the displayed delivery instructions and delivers the parts to the designated process.
[0036]
Next, it is determined whether or not the parts transport vehicle 26 has stopped at the process instructed to deliver the parts (S12). Information indicating in which process the parts carrier 26 has stopped is transmitted from the parts carrier 26 to the production instruction computer 23.
[0037]
When the parts transport vehicle 26 stops at the designated process (S14, YES), the process proceeds to step S15 to check and record which parts and how many parts have been delivered to the target process instructed for delivery. Then, from the quantity of parts used in the produced product and the quantity of parts actually delivered to each process, it is calculated which parts are currently in stock in each process (S16). ).
[0038]
If the parts transport vehicle 26 is not stopped in the instructed process (S14, NO), the process proceeds to step S17, and records that no parts have been replenished in that process (and the produced product). From the quantity of used parts, it is calculated which parts are currently in stock in each process (S18).
[0039]
By the above processing, the inventory of parts in each process can be grasped in real time.
According to the first embodiment, by reading the barcode given to the product by the barcode reader 22 installed in the production line, the types of parts produced and used for all products and the respective parts You can know the quantity used in real time. Furthermore, it is possible to know the quantity of parts delivered to each process. Therefore, the inventory of parts in each process can be accurately calculated from the quantity of parts used for production and the quantity of parts delivered to each process. Therefore, it is possible to instruct delivery of parts at an appropriate timing so as not to run out of parts in each process. This eliminates the need to place extra parts in each process in consideration of delays in parts delivery, and can greatly reduce parts inventories throughout the factory.
[0040]
In addition, the production instruction computer 23 acquires information indicating which process of the parts transport vehicle 26 has stopped in the production line from the parts transport car 26, and is used for the information, the quantity of parts delivered to each process, and production. The inventory quantity of parts in each process can also be calculated based on the used quantity of each part. In this case, since the quantity of parts actually delivered to the process can be grasped, the inventory of each process can be grasped more accurately.
[0041]
In the first embodiment described above, the case where a barcode is recorded for each product and the barcode is read for each product has been described. However, the barcode need not necessarily be recorded for each product. For example, when multiple types of products with different specifications are produced on a single production line, it is possible to obtain information that identifies the product when manufacturing is started, or a bar code is added to the first product on the production line. The bar code may be recorded and read, and the product production quantity may be counted by a sensor or the like. Even in this case, it is possible to calculate the parts used in the product and the used quantity from the information specifying the product to be produced and the production quantity, and further calculate the inventory quantity of the parts in each process.
[0042]
Next, a second embodiment of the present invention that manages the inventory of parts in each process more accurately by reflecting defect information obtained by inspection will be described.
FIG. 5 is an explanatory diagram of the inventory management method of the process according to the second embodiment. In the production system of the second embodiment, the barcode reader 41 is provided in the intermediate inspection process in the middle of the production line 21, and the barcode reader 22 described above is provided in the finished product inspection process. When a defect is found in the intermediate inspection process or the completion ratio inspection process, a barcode read by the barcode reader 41 or 22 is transmitted to the production instruction computer 23.
[0043]
The host computer 42 determines a monthly production instruction, a delay or advance with respect to the monthly production instruction, gives a production plan change instruction to the production instruction computer 23, and when it finds a continuous defect from the inspection information, Instruct the cause analysis.
[0044]
The production instruction computer 23 calculates the number of parts used in the defective product from information on the defective product obtained from the intermediate inspection process or the finished product inspection process, and the parts used in the finished product obtained from the finished product inspection process. The quantity of parts actually used in the process is calculated by adding the quantity of parts of the defective product to the quantity used. Then, the inventory of the parts in each process is obtained from the used quantity of the parts used in the process and the quantity of the parts delivered to each process by the parts transport vehicle 26.
[0045]
According to the second embodiment, when a defect is found at the intermediate inspection or finished product inspection stage, the quantity of parts in each process is calculated in consideration of the number of parts used in the defective product. Since it can obtain | require, the inventory of each process can be grasped | ascertained more correctly.
[0046]
Next, FIG. 6 is a flowchart showing a process of the production instruction computer 23 for realizing the inventory management method of the process according to the third embodiment of the present invention. In the third embodiment, the stock quantity of each process is calculated in consideration of the quantity of reusable parts among the parts used in the product in which the defect is detected in the inspection process. .
[0047]
The barcode reader 22 reads the barcode of the finished product (FIG. 6, S21), and the production instruction computer 23 develops the information at the part level based on the barcode (S22). These processes are the same as the processes in steps S11 and S12 of FIG. 4 described above.
[0048]
When a defect of the product or part is detected in the intermediate inspection or the finished product inspection, a reusable part is extracted (S23). Then, the number of reusable parts is subtracted from the used quantity of parts used in the finished product and the defective product, and which parts are used and how many times are used (S24).
[0049]
Further, the production instruction computer 23 instructs the parts transport vehicle 26 to deliver the parts to each process based on the production plan and the quantity of parts used in the production line (S25). Thereafter, it is determined whether or not the parts transport vehicle 26 has stopped in the process instructing delivery of the parts (S26).
[0050]
When the parts transport vehicle 26 stops at the designated process (S26, YES), the process proceeds to step S27 to record which parts and how many parts are delivered to the target process instructed for delivery. Then, subtract the quantity of reusable parts from the quantity of parts used for finished products and products that have failed inspection, and the quantity of parts actually delivered to each process, and then The inventory quantity of the parts is calculated (S28).
[0051]
On the other hand, when the parts transport vehicle 26 is not stopped in the instructed process (S26, NO), the process proceeds to step S29, and it is recorded that no parts are replenished in the process (S29). Then, the inventory quantity of the parts in the corresponding process is calculated from the value obtained by subtracting the quantity of reusable parts from the quantity of parts used for the finished product and the inspection rejected product (30).
[0052]
According to the third embodiment, the quantity of parts that can be reused among the parts that are used in the products that are rejected in the intermediate inspection or the finished product inspection is determined by the number of parts used in the rejected parts. By subtracting from the quantity, it is possible to obtain the actual part usage quantity excluding the quantity of reusable parts. And since the quantity of the parts delivered to each process can be calculated from the information of the parts delivered by the parts transport vehicle 26, the inventory of parts in each process can be accurately calculated in real time from these quantities. As a result, a necessary number of parts can be supplied when necessary in each process, so that it is not necessary to have an extra parts inventory in each process of the production line 21, and parts inventory in the entire factory Can be reduced.
[0053]
As another embodiment of the present invention, the inventory of each process may be calculated in consideration of the quantity of parts used in the finished product on the production line.
That is, since the parts to be used in each process of the production line are known in advance, the number of parts incorporated in the finished product on the production line can be calculated.
And the total value of the number of parts incorporated into the finished product and the number of parts incorporated into the finished product (including rejected products) on the production line, that is, the parts actually used in each process Subtract the total quantity of the parts in each process before the start of production from the sum of the parts delivered to each process and the exact quantity of parts in each process. Is calculated.
[0054]
By doing so, since the inventory quantity of each process can be known more accurately, a necessary number of parts can be delivered when necessary so that there is no missing part in each process.
[0055]
The present invention is not limited to the above-described embodiment, and may be configured as follows.
(A) The method of reading information for specifying a product is not limited to a method of optically reading a barcode or the like recorded on a product or a medium attached to the product, but information such as a model number recorded on the product. You may make it read with an image sensor etc., You may make it read electrically the information recorded on storage media, such as information recorded magnetically, or a contact or non-contact type IC card. Alternatively, an ID tag or the like having a wireless transmission function may be attached to the product and an ID code specifying the product may be received.
(B) Information for specifying a product does not necessarily need to be given to each product, and the information may be notified to the production instruction computer 32 or the like at the start of product production.
(C) When the delivery quantity of one part is determined, the production instruction computer 23 notifies the parts transport vehicle 26 of the delivery instruction every time a part of the quantity for one delivery is used. Also good. In this case, it is not necessary to specify the quantity in the delivery instruction. If the delivery quantity for each part type is different, set and manage the correspondence between the part type and the delivery quantity, and compare the used quantity of the parts used in the product with the delivery quantity of the corresponding part. The delivery instruction may be made based on the above.
(D) The present invention can be applied not only to a conveyor type production line but also to a production method such as group production with a small number of people who does not use the line.
[0056]
【The invention's effect】
According to the present invention, it is possible to accurately grasp the inventory of parts in each process. As a result, a necessary number of parts can be delivered to each process when necessary so as not to cause missing parts. Accordingly, it is not necessary to have an excessive part inventory in each process, so that the inventory quantity of parts can be reduced. Furthermore, since the kanban is not used, not only the operation of creating the kanban is unnecessary, but also there is no delay in parts delivery due to the time taken to collect the kanban or the lack of parts due to the loss of the kanban.
[Brief description of the drawings]
FIG. 1 is an explanatory diagram of an inventory management method of a process according to a first embodiment.
FIG. 2 is an explanatory diagram of wireless communication of a parts transport vehicle.
FIG. 3 is a diagram illustrating a stop position in a production line for a parts transporter.
FIG. 4 is a flowchart illustrating processing of a production instruction computer according to the first embodiment.
FIG. 5 is an explanatory diagram of an inventory management method of a process according to the second embodiment.
FIG. 6 is a flowchart illustrating processing of a production instruction computer according to the third embodiment.
FIG. 7 is an explanatory diagram of a conventional Kanban type parts delivery method.
[Explanation of symbols]
21 Production Line 22 Barcode Reader 23 Production Instruction Computer 25 Inventory Management Computer 26 Parts Carrier 41 Barcode Reader 42 Host Computer

Claims (3)

Obtaining the parts used in the finished product and the rejected product and the quantity of the part based on information for identifying the product and information on the rejected product determined to be rejected in the inspection process;
  Based on the quantity of the finished product and the rejected product and the quantity of parts used in the finished product and the rejected product, the usage quantity of each part used in the finished product and the rejected product is calculated,
  A process inventory management method, comprising: calculating an inventory quantity of a part in each process based on the used quantity of each part and information on a part delivered to each process. Calculate the quantity of parts to be delivered to each process based on the inventory quantity of parts in each process and information about the parts delivered to each process, and transport the information indicating the delivery destination process and the quantity of parts to be delivered 2. The process inventory management method according to claim 1, wherein the inventory control method is displayed on a display device of a car. Obtain information that indicates whether the parts carrier has stopped at the destination process to deliver the parts,
Calculating a stock quantity of components of the respective steps, acquired when the information is the part transportation vehicle indicates that it has stopped the delivery destination process, information about the parts delivered to the delivery destination of the process 2. The process inventory management method according to claim 1, wherein the inventory quantity of the parts in the process is calculated based on the used quantity of each part used for the finished product and the rejected product .

Images