JP4175119B2 - Parts ordering device, ordering method and program therefor - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a technology for ordering parts for a line for assembling parts one after another to members conveyed one after another to a part assembling position and producing products one after another. For example, wheels (parts) are assembled one after another to automobiles (members) being assembled that are successively conveyed to a wheel assembly position (parts assembly position) by a belt conveyor system, and automobiles (products) are produced one after another. The present invention relates to a technology for ordering wheels (parts) for an automobile production factory (production line).
The “product” here refers to a product produced by assembling parts to members. Typically, it is the final product, but in a production line that produces an intermediate product, the intermediate product is the product. For example, an engine is a product for an engine production factory and a part for an automobile production factory. The member refers to a member that is transported from the component assembly position to the next component assembly position, and a product is produced by assembling the component to the member.
[0002]
[Prior art]
For example, in an automobile production factory, parts such as doors, hoods, glass, sheets, engines, etc. are assembled to painted bodies (members) to complete the automobile (product). In this case, the parts are often produced at a place different from the automobile production factory. For example, it is produced in a production plant that specially produces parts, or in a production line that is separate from the automobile production line.
Many product production lines produce products using parts that are produced elsewhere and delivered to the product production line. Therefore, in the product production line, parts to be used in the product production line must be ordered. In this case, it is necessary to order the parts appropriately so that the ordered parts are not overstocked or missing. A technique for ordering an appropriate quantity at an appropriate timing is required.
[0003]
In the case of producing a product while conveying a large number of members by a belt conveyor system, a part ordering technique called a construction replenishment system can be used (for example, Patent Document 1). In this construction replenishment method, an ordering position is provided upstream from the part assembly position of the transport line for transporting the member, and when the member is transported to the ordering position, a part for a product to be produced using the member is placed. Order. At this time, the time required for the member transported to the ordering position to move to the part assembly position is equal to the time required for the part to arrive at the part assembly position after the part is ordered. To do. According to this method, when a member reaches the component assembly position, the necessary component should reach the component assembly position, and it is possible to prevent the occurrence of a shortage without having a stock.
[0004]
[Patent Document 1]
Hei 4-152053
[0005]
If the time required from when a part is ordered until the part arrives at the part assembly position becomes long, the ordering position on the member transport line may be upstream from the start position of the member transport line. That is, it is assumed that the member is transported to the ordering position that does not actually exist, and the time at which the virtual member is transported to the virtual ordering position is obtained (this time can be actually obtained), and the time It is necessary to order parts. In this case, since the product type cannot be specified from the members that have actually arrived at the ordering position, a production order plan that stores the order of the types of products that are successively produced on the production line is required.
If the order of the types of products to be produced is known, the time at which virtual parts are transported to the virtual ordering position and the type of products to be produced using those parts will be known. You can place an order at any time. Even with this ordering technique, it is possible to place an order so that a necessary part reaches the part assembly position when the member reaches the part assembly position.
[0006]
[Problems to be solved by the invention]
By the above-described start-up replenishment method, that is, a method of ordering parts types necessary for production of products produced using the members at the time when the members are transported to a real or virtual ordering position, the product production pace is increased. As long as there is no change, parts shortage can be prevented without having parts inventory.
However, the pace of use of parts at the part assembly position may vary. In particular, the part where the part is assembled is temporarily held downstream of the part assembly position (that is, between the part assembly position and the end of the production line) to temporarily adjust the product production pace on the production line. When the holding band is provided, the usage pace of the component at the component assembly position varies. When the semi-finished product held in the temporary holding zone is eliminated, the use pace of the parts at the parts assembling position is lowered. In order to increase the number of semi-finished products held in the temporary holding zone, the part use pace is increased by increasing the conveying speed of the members.
If the ordering position is set in accordance with a constant and stable predetermined conveying speed such as the standard conveying speed of the member, it is necessary even if the member reaches the part assembly position when the conveying speed of the member is increased. The part will not arrive at the part assembly position, and the part will be missing.
[0007]
In view of the above points, while maintaining a method for ordering the types of parts necessary for the production of products produced using a member at the time when the member is transported to a real or virtual ordering position, the member transport speed There is a need for a technique that prevents parts from running out even if the parts usage pace increases or decreases in conjunction with the increase or decrease in the number of parts.
[0008]
[Means, actions and effects for solving problems]
  The ordering device according to claim 1 is manufactured by assembling parts one after another to a member conveyed one after another to a part assembling position and producing products one after another, and increasing / decreasing the conveying speed within a range below the maximum speed. Production line to adjust paceA production line provided with a temporary holding band for temporarily holding a member in which a part is assembled between its final end and the part assembling position to adjust a product production pace in the production line.For ordering parts for andNon-existent virtualWhile maintaining the method of ordering the types of parts required for the production of products that are produced using the members when the members are transported to the ordering position, the parts usage pace is linked to the increase / decrease in the transport speed of the members. Place orders so that parts will not run out even if the number increases or decreases.
  Here, the “maximum speed” is not the maximum speed that can be operated on the physical function of the production line, but the maximum speed that can be increased to adjust the production pace. .
  This ordering deviceProduction sequence plan storage means for storing the types of products produced one after another on the production line in association with the serial numbers of the production sequence;A product / part type storage means for storing a part type used for production of the product in association with the product type;Virtual ordering position conveying member type specifying means for specifying the type of product to be produced using the members conveyed to the virtual ordering position each time production of the product proceeds virtually according to the production sequence plan Ordering means to order parts for different types of products;It has.The type of product to be produced using the parts that have been transported to the virtual ordering position can be specified from the production sequence plan, and the type of part used for product production is stored in the product / part type storage means. Can be identified from The ordering unit places an order for a part that is assembled at the assembly position in the product type specified by the virtual ordering position conveying member type specifying unit.
  The ordering device of the present invention is characterized by its ordering position.One. The ordering position is
(1) At a position where a predetermined number of parts are in stock at the part assembly position while the member conveyance speed is a predetermined speed less than the maximum speed.As well as
(2) When the member transport speed is increased from the predetermined speed to the maximum speed, the parts ordered at a speed corresponding to the maximum transport speed of the member are not assembled before the predetermined number of parts inventory is depleted. A position to arrive at the attachment position, and
(3) The serial number of the product to be produced by using the member existing at the part assembly position, the number n of unreserved parts on the production line temporarily reserved, and after the part is ordered until the part arrives at the part assembly position The product corresponding to the serial number obtained by adding the number of members conveyed during the lead time is set at a position where the product virtually exists.
[0009]
When the member conveyance speed is stable at a predetermined speed (for example, a standard conveyance speed when the production line is operated in a normal state), the number of parts stocked at the part assembly position is determined by the ordering position.
(A) If the time required for the member conveyed to the ordering position to move to the part assembly position is equal to the time required for the part to arrive at the part assembly position after ordering the part Inventory does not increase or decrease.
(B) The time required for the member transported to the ordering position to move to the part assembly position is longer than the time required for the part to arrive at the part assembly position after ordering the part. In other words, if the ordering position is shifted upstream from the case (a), the parts inventory increases to a predetermined number.
This phenomenon is illustrated by a simple example. The member transport line transports the member to the component assembly position at a rate of one per 10 minutes. It takes 100 minutes for the part to arrive at the part assembly position after ordering the part.
If the ordering position is provided at a position where the member passes the ordering position and is transported to the part assembling position 100 minutes later, the number of parts in stock at the part assembling position does not increase or decrease (corresponding to the above a). If the initial parts inventory is zero, it is maintained as zero.
If the ordering position is provided at a position where the member passes to the ordering position 110 minutes after passing the ordering position, the number of parts in stock at the part assembly position increases by one (corresponding to b above). . If the initial parts inventory is zero, the number is increased to one and thereafter one inventory is maintained.
If an ordering position is provided at a position where the member passes the ordering position and is transferred to the part assembly position 120 minutes later, the number of parts in stock at the part assembly position increases by two (corresponding to b above). . If the initial parts inventory is zero, the number is increased to two, and thereafter, the inventory of two is maintained.
If the ordering position is provided at a position where the member passes the ordering position and is transported to the part assembling position 130 minutes later, the number of parts in stock at the part assembling position increases by three (corresponding to b above). . If the initial parts inventory is zero, the number of parts increases to three, and thereafter the inventory of three is maintained.
[0010]
If the member conveyance speed increases and the part use pace increases, the number of parts in stock at the part assembly position decreases. In this case, the number of parts in stock at the parts assembling position decreases until the parts ordered at an increased pace corresponding to the increase in the conveying speed of the parts arrives at the parts assembling position. Maintained.
This phenomenon is illustrated by a simple example. The member transport line was increased from a certain predetermined speed for transporting a member to the part assembly position at a rate of one per 10 minutes to a speed for transporting a member to the part assembly position at a rate of one per 8 minutes. And Here, this speed increase speed is the maximum speed. Also, assume that it takes 100 minutes for a part to arrive at the part assembly position after ordering the part. Immediately after the increase in speed, parts arriving at the pace before the speed increase are used at the speed after the speed increase, so the number of parts in stock decreases. In this case, 0.125 parts arriving at one minute are used at 0.125 parts per minute, and the number of parts in stock decreases at a pace of 0.025 parts per minute.
If the ordering position is provided at a position where the member passes to the ordering position 100 minutes after passing the ordering position, 0.125 parts will arrive per minute after 100 minutes from the speed increase. After that, the number of parts in stock will not decrease. In this case, the number of parts stock decreases by 2.5 in 100 minutes, and thereafter the parts stock is kept constant.
From the above, when the parts usage pace is a times the delivery pace (a times the previous transport speed), the immediately preceding parts usage pace (pieces / hour) x time from ordering to arrival (time) x The number of parts obtained by the expression (a-1) (denoted as expression F1) is reduced. On the other hand, the parts use pace is 0. 0 with respect to the delivery pace. When it becomes b times (0b times the immediately preceding conveyance speed), the following formula (Previous component usage pace (pieces / hour) × Time from ordering to arrival (time) × (1-0.b)) The number of parts obtained by the equation (F2) will increase.
[0011]
In the case of the above example, if the ordering position is provided at a position where the member is transported to the part assembly position 125 minutes after passing the ordering position, the following phenomenon occurs.
(C) From (b) described above, the number of parts in stock at the part assembling position increases by 2.5 while the predetermined speed for conveying the member to the parts assembling position at a rate of 1 every 10 minutes continues. To do. If the initial parts inventory is 0, the inventory is increased to 2.5 and thereafter the inventory of 2.5 is maintained.
(D) In this state, when the speed is increased to the maximum speed at which the member is conveyed to the part assembly position at a rate of 1 every 8 minutes, the number of parts in stock decreases at a pace of 0.025 per minute. The parts inventory will decrease for 100 minutes, and will eventually decrease by 2.5. This can be confirmed from the above formula F1. After that, the parts inventory will not decrease. That is, the parts inventory becomes zero after 125 minutes, and is maintained at zero thereafter. The circulation of production using the arrived parts is maintained, and production can be continued without having parts inventory.
(E) When the speed returns to the predetermined speed at which the member is transported to the part assembly position at a rate of 1 every 10 minutes, the state returns to the state of (c) above and the number of parts in stock reaches 2.5 from the above formula F2. The inventory number is maintained after the increase. Therefore, as shown in (d), it is possible to secure a parts inventory that does not run out even if the parts inventory decreases.
[0012]
  The ordering device of the present invention is characterized by the ordering position,In (1) and (2)As illustrated, it is a position where a predetermined number of parts stock can be obtained at the parts assembly position while the member transport speed is less than the maximum speed, and the member transport speed is changed from the predetermined speed to the maximum speed. When the speed is increased, the parts ordered at a speed corresponding to the maximum conveying speed of the members are set at a position where the parts arrive at the parts assembly position before the predetermined number of parts inventory is depleted. Therefore, even if the conveyance speed of the member is increased to the maximum conveyance speed, parts are not missing. Moreover, even if the member conveyance speed is a constant predetermined speed, it is only increased to the number of stocks that need to be secured in preparation for an increase in the member conveyance speed, and does not increase excessively. No inventory issues.
[0014]
  According to the ordering device of the present invention, it is possible to maintain a method of ordering the part types necessary for production of products produced using the members at the time when the members are transported to the virtual ordering position. Even if the component usage pace increases or decreases in conjunction with the increase or decrease in the conveying speed of the members, it is possible to place an order so that the components will not run out.
  Moreover, according to the ordering apparatus of the present invention,Even if the parts conveyance speed increases and the parts usage pace increases while the constant specified conveyance speed is maintained, the parts inventory is sufficient so that the parts will not run out. Can be prepared. Even if a certain predetermined conveyance speed continues for a long period, it will only increase to the number of inventory that needs to be secured in preparation for the increase in the conveyance speed of the members, and the inventory quantity will not increase excessively, so it will be overstocked No problem arises.
[0016]
The conveying speed of the members, that is, the usage pace of the parts does not fluctuate unnecessarily, but the parts usage pace at the part assembly position may increase. When it increases, the member in which the parts are assembled stays downstream. A temporary holding zone is provided to adjust the product production pace on the production line by temporarily holding the parts with the parts assembled downstream from the part assembly position, that is, from the end of the production line to the part assembly position. If it is, the conveying speed of the member can be increased or decreased within the range of the number of members that can be held in the temporary holding zone.
When adjusting the product production pace using a temporary holding zone, a unit period for adjustment is set. For example, when 5 units can be held in the temporary holding zone, it is determined that the number of holdings is increased or decreased during a unit period such as half a day or one day, and the number of holdings is not greatly increased or decreased in a short time. If the unit period is 1 day, the maximum conveyance speed set for adjusting the production pace is obtained by adding the speed of 5 units / day to the predetermined conveyance speed of a certain member. In this case, it is possible to change from a state that is not held in the temporary holding zone to a state where 5 units are held after one day. Since there is a temporary holding zone that can hold 5 cars, the speed can be increased by the speed of 5 cars / day.
If the ordering position is determined by setting the difference between a certain member's predetermined transport speed and the maximum transport speed according to the number of possible suspensions in the temporary suspension band, the use pace of the parts is increased or decreased using the temporary suspension band. In this case, parts are not missing or overstocked.
[0017]
  For example,It takes a long time from ordering a part until it arrives at the part assembly position. At the time when the virtual member is transported to the virtual ordering position,The parts to be assembled at the assembly position when the member is transported to the assembly positionWhen placing an order, use a member that has been transported to a virtual ordering position by executing a process equivalent to transporting a member on a virtual production line according to a production order plan each time production of the product proceeds. It is necessary to identify the type of product to be produced.In the ordering device of the present invention, production is performed using a member that has been transported to a virtual ordering position each time production of a product virtually proceeds according to the production order plan based on the storage contents of the production order plan storage means. The product type is specified by the virtual ordering position conveying member type specifying means. The parts for the specified type of product can be specified based on the stored contents of the product / part type storage means, and the ordering means uses the parts to be attached to the specified product type at the above assembly position. If so, order parts for that type of product. At this time, the ordering position satisfies the above conditions (1) and (2), and (3) the part number from the end of the production line to the serial number of the product produced using the member existing at the part assembly position. The unreserved number n of the temporary holding belt provided between the pumping position and the number of members conveyed within the lead time from when the part is ordered until the part arrives at the part assembling position. It is set to a position that also satisfies the condition that the product corresponding to the added serial number is a virtual position.
  In this case, the difference between the serial number of the product produced using the member that has advanced to the end of the production line and the serial number of the product produced using the member at the order position isWhen the number n of non-holdings in the temporary holding zone of the production line and the number of members conveyed within the above lead time are stableThe part type to be ordered can be determined from the serial number of the product that is always constant and has progressed to the end of the production line. In other words, it is possible to place an order based on product information for which production has been completed on the production line.
[0021]
  The present inventionIt is a production line that adjusts the production pace by assembling parts one after another to the parts that are transported one after another to the parts assembly position and producing products one after another, and increasing or decreasing the transport speed within the range of the maximum speed or less. Parts for production lines that have a temporary holding zone that adjusts the product production pace in the production line by temporarily holding the parts with the parts assembled between the rear end and the part assembly position Can be embodied in a program for a computer ordering.
  The program for ordering parts created in the present invention is:The following processing is performed on the computer, that is, processing for referring to production sequence plan data describing the types of products successively produced on the production line in association with the serial numbers of the production sequence, and the products in association with the product types. Order the parts to be processed, referencing the product / part type data describing the part type, and the serial number of the product to be produced using the parts existing at the part assembly position, and the number of parts in the temporary holding zone of the production line and n parts. Processing to calculate the position where the product corresponding to the serial number, which is the sum of the number of members conveyed during the lead time from when the part arrives at the part assembly position, to the virtual position, as the ordering position and production Each time the production of a product progresses virtually according to the sequence plan, the process for identifying the type of product to be produced using the material conveyed to the virtual ordering position and the type of product The type of products that are identified by the process of the constant to, characterized in that to execute a process of ordering the part when the part to be assembled at the assembly position has been used. According to the present invention, the ordering device described above can be realized.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
First, an embodiment to which the present invention is suitably applied will be described.
(Embodiment 1) The difference between the minimum number and the maximum number of parts to be stocked at the part assembly position can be determined as an arbitrary difference desired by the product production company. For example, the difference can be increased if fluctuations in the usage pace of the parts are expected to increase. Conversely, if it is expected that fluctuations in the usage pace of parts will be reduced, the difference can be reduced.
[0023]
【Example】
With reference to FIG. 1, the outline | summary of the production line in a present Example is demonstrated. The production line 2 includes a main body member production line 4 that produces main body members, and an assembly line 6 that assembles parts to the main body members carried in from the main body member production line 4. The assembly line 6 includes a plurality of assembly steps and a plurality of temporary holding belts that adjust the production pace of products in each assembly process by stocking a main body member that is provided between the assembly processes and that has parts assembled thereto. It consists of.
The assembly line 6 includes an assembling process A located at the uppermost stream, an assembling process B located after the assembling process A, an assembling process C located after the assembling process B, and a most downstream position. Assembly step D. Different types of parts are assembled in each assembly process. In this embodiment, the part a is assembled in the assembly process A, the part b and the part e are assembled in the assembly process B, the part c is assembled in the assembly process C, and the part d is assembled in the assembly process D. wear. A sensor H is provided at the most advanced carry-in port H of the assembly line 6 for grasping how many main body members have been put into the assembly process. A sensor N is provided at the rear end of the assembly line 6 and the outlet N of the rear end of the production line 2 to grasp how much the product having the parts assembled to the main body member is completed and carried out. Yes. When the number obtained by the sensor N is subtracted from the number obtained by the sensor H, the number of main body members existing in the assembly line 6 can be obtained. Further, sensors for ascertaining when and when which main body member has been conveyed are provided at the position where each component is assembled (sensors a, b, c, d, e). With these sensors, it is possible to detect the pace of use of the parts assembled to the main body member. These sensors serve as body member grasping means 22 described later.
The assembly line 6 is provided with a temporary holding band 1 between the assembling process A and the assembling process B, and a temporary holding band 2 is provided between the assembling process B and the assembling process C. A temporary holding band 3 is provided between the process C and the assembly process D. These temporary holding zones are provided for adjusting the respective product production paces when a situation occurs in which the product production paces of adjacent assembling processes differ. Therefore, when all the product production paces in the adjacent assembling steps are normal, the temporary holding zone is not used and is empty.
The number of main body members that can be received by the main body member production line 4 and the assembly line 6 is determined. The production line 2 is provided with addresses (addresses) corresponding to the order counted upstream through the production line 2 starting from the last carry-out port N. For example, in the assembly line 6, the most downstream assembly process D can accept 50 body members, and addresses 1 to 50 are assigned. The part d is assembled at the address 25. The temporary holding belt 3 can receive five main body members, and addresses 51 to 55 are given. Thus, a total of 200 body members can be received in the assembly steps A, B, C, and D of the assembly line 6, and a total of 15 body members can be received in the temporary holding bands 1, 2, and 3. it can. Therefore, the assembly line 6 can receive a maximum of 215 body members in total.
[0024]
Next, with reference to FIG. 2, a system configuration of an embodiment of a parts ordering apparatus embodying the present invention will be described.
The part ordering apparatus 10 is connected to a management computer 30 of a production company and a computer 40 of a part production process so as to communicate with each other via a network.
[0025]
The product type / part type storage unit 12 provided in the part ordering apparatus 10 stores a part type used for production of a product of that type in association with the product type.
The production order plan storage unit 14 stores a plan of the order of the types of products produced on the production line. The production order plan is transmitted from the management computer 30 of the production company at a predetermined time.
FIG. 3 shows a composite of product type / part type information for products produced on the production line 2 and a production order plan from September 30 to October 2. FIG. 4 shows a composite of product type / part type information and a production order plan from October 3 to October 4. The third row from the top of the table shows the production order plan. The top row shows the time when the production of each product is completed. From the time when production is completed, the operation time of the production line becomes clear. In the case of the production line 2, since the production of the first product is completed at 8:00 and the production of the last product is completed at 23:00, it can be seen that the operation time is 15 hours. The second row shows the serial number of each product. The serial number makes the planned production number clear. For example, in the case of September 30, it is understood that the plan is to produce 300 products from serial number 701 (no. 701) to serial number 1000 (no. 1000). In the third row, identification information of products produced by each serial number is shown. α, β, γ, etc. represent product types, and numbers represent identification numbers including serial numbers and specifications. Corresponding to the third row of the table, the fourth and subsequent rows show product type / part type information. In the fourth row, identification information of the main body member used for each serial number product is shown. Bα, Bβ, Bγ, and the like represent the types of the main body members, and numerals represent identification numbers including serial numbers and model numbers corresponding thereto. In the lower part, identification information of parts to be assembled to the main body member is shown. “a”, “b”, “c”, “d”, etc. represent the types of parts, and the identification numbers including serial numbers and product numbers corresponding to numbers.
The standard transport speed information storage unit 16 in FIG. 2 stores information on standard transport speed when the production line is operated in a normal state set in advance. This standard transport speed is set according to the production plan, the number of workers, and the like. In this embodiment, the standard transport speed is set to 20 / hour.
In the arrival lead time / arrival lead time conveyance number information storage unit 18, the time required from the time the part is ordered until the ordered part arrives at the part assembly position, and the production line within the time is the standard conveyance speed. Is stored in association with information on the number of main body members to be conveyed. In this embodiment, the arrival lead time is determined to be 15 hours in consideration of the lead time from ordering to delivery and the safety time based on the planned production number of the product specified in the above-described production sequence plan. The number of conveyances between arrival lead times is obtained by multiplying the arrival lead time by the standard conveyance speed (number of main body members / hour, stored in the standard conveyance speed information storage unit 16). In the case of the assembly line 6 of the production line 2, the standard conveyance speed is set to 20 pieces / hour, so that the arrival lead time is 15 hours × the conveyance speed is 20 pieces / hour = 300 pieces.
As described above, an address (address) is assigned to the assembly line 6. If a part is assembled at the address 1 position, when the part is ordered when the body member to which the part is assembled is at the address 300, the body member is assembled to the body member when the body member is transported to the address 1 position. The part to be attached arrives at address 1. The address 300 may be upstream from the carry-in entrance H and may not actually exist. In that case, it must be considered virtually.
[0026]
The parts ordering device 10 determines the number of parts to be stocked at the parts assembly position based on the information in the standard transport speed storage unit 16 and the information in the arrival lead time / arrival lead time transport number storage unit 18. There are provided inventory part number calculating means 20 for calculating and main body member grasping means 22 for grasping main body members existing in the production line. Further, based on the information in the product type / part type storage unit 12 and the information in the production order plan storage unit 14, a process corresponding to the conveyance of the members in the virtual production line according to the production order plan is executed. Virtual order position transport member type specifying means 24 for specifying the type of product to be produced using the members transported to the virtual order position is provided. Furthermore, an ordering unit 26 is provided for ordering parts for a product to be produced using a member that has been transported to an actual ordering position on the production line or a virtual ordering position. The ordering information from the ordering means 26 is transmitted to the computer 40 in the parts production process via the network.
[0027]
In the following embodiment, since the product type δ starts to be newly produced on October 1, an example in which the present invention is applied when ordering a part e that is newly required as a part used for the product type δ. Will be explained. The period in which the part e is used is from October 1 to October 4, and the period for ordering the part e is from September 30 to October 3.
In the following embodiments, it is assumed that products are produced as planned in the production order plan and the order is not changed. In addition, the actual production number of each day is assumed to be the planned production number.
[0028]
In this embodiment, while the conveying speed of the main body member is the standard speed (corresponding to the above-mentioned “predetermined speed less than the maximum speed”), there is an inventory of 10 parts e at the assembly position of the parts e. An ordering position is provided at the position to be performed. The number of 10 is the number of temporary holding bands 2 and 3 that can be held between the rear end of the production line 2 and the assembly position of the part e. Even if the stock of parts e is reduced within this number range by increasing to the maximum transport speed (corresponding to the above-mentioned “maximum speed”) obtained by adding the speed of 10 pieces / day to the standard transport speed, The part e can arrive at the assembly position without any shortage. In addition, since the temporary holding zones 2 and 3 are the numbers that can be held, it is not necessary to provide an inventory space separately from the production line 2. On the other hand, even if the conveyance speed is increased and the number of stocks reaches zero, and then returns to the standard conveyance speed, the number of parts in stock is only increased to 10, so there is no fear of overstocking. The number of parts in stock is calculated in advance by the number of parts in stock calculation unit 20 of the part ordering apparatus 10.
According to the technique of the present invention, the ordering position is always set at a constant position regardless of whether or not the conveyance speed of the main body member has fluctuated. In the present embodiment, the ordering position is provided at a position where the inventory of ten parts e exists at the assembly position of the parts e during the standard speed. Conventionally, a process of updating the order position every day has been performed. In the following embodiments, even if the update process is performed every day as in the prior art, the order position is always set at the above-described fixed position, and the order is placed based on the order position thus set.
[0029]
FIG. 5 shows the main body members present in the assembly line 6 at the end of the operation time of the production line 2 on September 29 (23:00). At this time, based on the main body member existing at the part assembly position, an order position for placing an order for the part e to be assembled from October 1st on September 30 is set.
At this time, the main body member scheduled to be carried out as a product from the carry-out port N on September 30 remains. Specifically, there is a body member Bα 701 used for the product of serial number 701 whose production is first completed on September 30 at the location of address 1, and production is completed on September 30 until the location of address 215 below. There is a body member that is used in the product (see FIG. 3). In order to produce 300 units on September 30, the main body members for the products of serial number 916 and later produced on September 30 have not yet been put into the assembly line 6, and the main body member production line 4, Alternatively, a virtual production line must be considered.
[0030]
Based on the flowchart of FIG. 9, the procedure of a part ordering process is demonstrated. In this flowchart, steps S2 to S6 are performed prior to actually placing an order for parts, and step S8 is performed when actually placing an order for parts. In the above example, in order to place an order for the part e to be assembled from October 1, the process from step S2 to step S6 is performed at 23:30 on September 29, and the process of step S8 is performed on September 30. Shall be done from the day.
First, in step S2, the main body member present at the part assembly position is grasped. In FIG. 5, the assembly position of the part e is the address 111, and it is understood that the main body member existing at that position is Bα 811 used for the product of serial number 811.
Next, in step S4, the number n of unreserved temporary suspension zones is acquired from the serial number corresponding to the main body member grasped in step S2. In the above example, the body member Bα 811 corresponding to the serial number 811 is grasped. The serial number 811 is the first serial number 701 to 111th as the serial number on September 30 from the production sequence plan of FIG. Therefore, it can be seen that the assembly processes B, C, D from the last end of the production line 2 to the part assembly position, and the temporary holding bands 2 and 3 are all filled, and the temporary holding band unretained number n is 0. Pieces are acquired. Also in FIG. 5, the temporary holding zones 2 and 3 are all buried.
[0031]
Next, in step S6 of FIG. 9, an order position is set. In this embodiment, a member used for a product corresponding to a serial number obtained by adding an unreserved number n and a transport number between arrival lead times to a serial number of a product produced using a main body member present at a part assembly position. Is set as the ordering position.
First, in FIG. 5, the main body member present at the assembly position of the part e is Bα811 corresponding to the serial number 811. The product corresponding to the serial number obtained by adding the unreserved number 0 and the number of conveyances between arrival lead times (300) to the serial number 811 is the serial number 111 of the plan to be produced on October 1 from the production sequence plan of FIG. Product. The position where this product exists is set as the ordering position. The position where the product having the serial number 111 exists is a position that goes back 300 addresses from the part assembly position (address 111), and is the position of the address 411. However, only the address 215 is assigned to the assembly line 6. If there is a position of the address 411 in the main body member production line 4, that position can be set as the ordering position. Otherwise, the virtual ordering position conveying member type specifying means 24 in FIG. 2 uses the main body member that is virtually conveyed to the ordering position set at the position corresponding to the address 411 on the production order plan. It is also possible to specify the product type to be used.
In this embodiment, it is assumed that the address 411 is located on the main body member production line 4. FIG. 5 shows that the position of the address 411 is set as the ordering position.
[0032]
In the subsequent step S8, the part e is ordered based on the ordering position. In step S6, the position of the address 411 is set as the ordering position. Information on the parts to be assembled to the product existing at this position (the product with the serial number 111 planned to be produced on October 1) is acquired from the product type / part type storage unit 12. From FIG. 3, the part e is not assembled to the product produced using the body member Bα 111 having the serial number 111. Here, the operation start time of the production line 2 on October 1 is 8:00, and the first order time for the parts used on October 1 is 15 hours (arrival lead time) of 8:00 It is 17:00 on September 30, the previous day. The part e will not be ordered at 17:00 on September 30th. Similarly, a product produced using a main body member conveyed to the address 411 at 17:03, a product produced using a main body member conveyed to the address 411 at 17:06, and so on. Consider. However, in the production sequence plan on October 1, production of the product type δ starts from the serial number 151. Therefore, the use of the part e is started from the serial number 151 (shown in a shaded pattern). The time when the main body member corresponding to the serial number 151 reaches the position of the address 411 is 18:57 on September 30 and the part e151 is ordered for the first time at 18:57 on September 30.
As described above, the part e to be assembled on October 1 is ordered at 18:57 on September 30. FIG. 10 shows a list of parts e ordered on September 30. The order time is shown at the top of the table. The second row shows that the product produced using the parts to be ordered is completed on October 1, and the third row shows the serial number in the production sequence plan for that product. Has been. In the lower stage, products produced by serial numbers, main body members to be used, and parts e to be assembled are shown.
[0033]
Next, FIG. 6 shows the main body members existing in the assembly line 6 at the end of the operation time of the production line 2 on September 30 (23:00). At this time, based on the main body member existing at the part assembly position, the order position for ordering the part e to be assembled on October 2 is determined on October 1.
At this time, the main body member that is scheduled to be carried out as a finished product from the carry-out port N on October 1 remains. Specifically, there is a main body member Bα1 corresponding to serial number 1 for which production is first completed on October 1 at the position of address 1, and products whose production is completed on October 1 until the position of address 215 below. There is a main body member used for (see FIG. 3). That is, as a result of the adjustment of the conveyance speed of the assembly line 6 on September 30, it can be seen that the production of products from serial numbers 701 to 1000 has been completed as planned.
[0034]
Based on the flowchart of FIG. 9, the process for ordering the part e assembled | attached on October 2 is demonstrated. The process from step S2 to step S6 is performed at 23:30 on September 30, and the process of step S8 is performed from October 1.
First, in step S2, the main body member present at the part assembly position is grasped. In FIG. 6, it is understood that the assembly position of the part e is the address 111, and the main body member present at that position is Bα 107 used for the serial number 107 product.
Next, in step S4, the number n of unreserved temporary suspension zones is acquired from the serial number corresponding to the main body member grasped in step S2. In the above example, the main body member Bα 107 corresponding to the serial number 107 is grasped. The serial number 107 is the 107th serial number from the first serial number 1 on the October 1st, based on the production sequence plan of FIG. Therefore, it can be seen that the four main body members of the temporary holding bands 2 and 3 are empty, and four of the temporary holding band unreserved number n are acquired. Also in FIG. 6, the addresses 54 and 55 of the temporary reservation zone 2 and the addresses 109 and 110 of the temporary reservation zone 3 are empty.
The 107th in this case exceeds the prescribed number (101) of acceptance of the assembly steps B, C, D downstream of the assembly position of the part e. This is because, after the production of products from serial number 701 to serial number 1000 is completed as planned, the transport speed of the assembly process upstream from the assembly position of the part e is faster than planned. This is because the main body member has remained. In this case, the same condition as when all of the temporary holding zones 2 and 3 are filled is added by adding four of the unheld numbers, and the ordering timing is advanced.
Next, in step S6, the order position is set. First, in FIG. 6, the main body member existing at the assembly position of the part e is Bα 107 corresponding to the serial number 107. The product corresponding to the serial number obtained by adding the unreserved number 4 and the number of conveyances between arrival lead times (300) to the serial number 107 is the serial number 411 of the plan to be produced on October 2 from the production sequence plan of FIG. Product. The position where this product exists is set as the ordering position. The position where the product of serial number 411 exists is a position that goes back 300 addresses from the part assembly position (address 111), and is the position of address 411. FIG. 6 shows that the position of the address 411 is set as the ordering position.
In subsequent step S8, parts are ordered based on the ordering position. In step S6, the position of the address 411 is set as the ordering position. Information on the parts to be assembled to the product existing at this position (the product with the serial number 411 planned to be produced on October 2) is acquired from the product type / part type information storage unit 12. From FIG. 3, the part e is not assembled to the product produced using the body member Bγ411 having the serial number 411. Therefore, the part e to be used for a product having a serial number after this is ordered.
FIG. 10 shows a list of parts e ordered on October 1.
[0035]
Next, FIG. 7 shows the main body members existing in the assembly line 6 at the end of the operation time of the production line 2 on October 1 (23:00). At this time, based on the main body member existing at the part assembly position, an order position for placing an order on October 2 for the part e to be assembled on October 3 is set.
At this time, the main body member scheduled to be carried out from the carry-out port N as a finished product on October 2 remains. Specifically, there is a body member Bα 301 used for the product of serial number 301 whose production is first completed on October 2 at the location of address 1, and production is completed on October 2 until the location of address 215 below. There is a body member that is used in the product (see FIG. 3). That is, as a result of the adjustment of the conveyance speed of the assembly line 6 on October 1, it can be seen that the production of products from serial number 1 to serial number 300 has been completed as planned.
[0036]
Based on the flowchart of FIG. 9, the process for ordering the part e assembled | attached on October 3 is demonstrated. The process from step S2 to step S6 is performed at 23:30 on October 1, and the process of step S8 is performed from October 2.
First, in step S2, the main body member present at the part assembly position is grasped. In FIG. 7, it is understood that the assembly position of the part e is the address 111, and the main body member existing at that position is Bα 401 corresponding to the serial number 401.
Next, in step S4, the number n of unreserved temporary suspension zones is acquired from the serial number corresponding to the main body member grasped in step S2. In the above example, the main body member Bα 401 corresponding to the serial number 401 is grasped. The serial number 401 is 101st from the first serial number 301 as the serial number on October 1 from the production sequence plan of FIG. Therefore, it can be seen that the temporary holding zones 2 and 3 are all empty, and ten of the temporary holding zone's unreserved number n are acquired. Also in FIG. 7, all the temporary holding zones 2 and 3 are empty.
The 101st in this case is the same as the prescribed number (101) of receiving steps in the assembly steps B, C, D downstream from the assembly position of the part e. This is because, even after the production of products from serial number 1 to serial number 300 is completed as planned, the conveying speed of the production line 2 is normal, and the assembly steps B, C, This is because the number of main body members as planned exists in D. In this case, the same condition as when all of the temporary holding zones 2 and 3 are filled is added by adding 10 of the unheld numbers, and the ordering timing is advanced.
Next, in step S6, the order position is set. First, in FIG. 7, the main body member present at the assembly position of the part e is Bα 401 corresponding to the serial number 401. The product corresponding to the serial number obtained by adding the unreserved number 10 and the arrival lead time conveyance number (300) to the serial number 401 is the serial number 711 of the plan to be produced on October 3 from the production sequence plan of FIG. It is a product. The position where this product exists is set as the ordering position. The position where the product with the serial number 711 exists is a position that goes back 300 addresses from the part assembly position (address 111), and is the position of the address 411. FIG. 7 shows that the position of the address 411 is set as the ordering position.
In subsequent step S8, parts are ordered based on the ordering position. In step S6, the position of the address 411 is set as the ordering position. Information on the parts to be assembled in the product existing at this position (the product with the serial number 711 planned to be produced on October 3) is acquired from the product type / part type information storage unit 12. From FIG. 4, the part e is not assembled to the product produced using the body member Bγ711 having the serial number 711. Therefore, the part e to be used for a product having a serial number after this is ordered.
FIG. 10 shows a list of parts e ordered on October 2.
[0037]
Next, FIG. 8 shows the main body members existing in the assembly line 6 at the end of the operation time of the production line 2 on October 2 (23:00). At this time, based on the main body member existing at the part assembly position, an order position for placing an order on October 3 for the part e to be assembled on October 4 is set.
At this time, the main body member scheduled to be carried out as a finished product from the carry-out port N on October 3 remains. Specifically, there is a body member Bα601 with serial number 601 for which production is first completed on October 3 at the location of address 1, and used for products whose production is completed on October 3 until the location of address 215. There is a body member to be applied (see FIG. 4). That is, on October 2, it can be seen that production of products from serial number 301 to serial number 600 was completed as planned.
[0038]
Based on the flowchart of FIG. 9, the process for ordering the part e assembled | attached on October 4 is demonstrated. The process from step S2 to step S6 is performed at 23:30 on October 2, and the process of step S8 is performed from October 3.
First, in step S2, the main body member present at the part assembly position is grasped. In FIG. 8, the assembly position of the part e is number 111, and it is understood that the main body member existing at that position is Bγ696 used for the product with serial number 696.
Next, in step S4, the number n of unreserved temporary suspension zones is acquired from the serial number corresponding to the main body member grasped in step S2. In the above example, the main body member Bγ696 corresponding to the serial number 696 is grasped. The serial number 696 is the 96th serial number from the first serial number 601 based on the production sequence plan of FIG. Therefore, it can be seen that the temporary holding zones 2 and 3 are all empty, and further, five main body members of the assembling steps B, C and D are empty. Also in FIG. 8, the temporary holding zones 2 and 3 are all empty, and in addition, the addresses 49 and 50 of the assembly process D and the addresses 105 to 105 of the assembly process C are empty.
In this case, when there is an empty in the assembly line 6 exceeding the number n of unreserved zones in the temporary holding zone, in addition to the number 10 of unreserved, further add 5 for the empty portion of the assembly process, We will make adjustments.
The 96th in this case is less than the specified number (101) of receiving steps B, C, D downstream of the assembly position of the part e. This is because assembling processes B and C are the result of the transfer speed of the assembling process upstream from the assembling position of the part e being slower than planned after the production of products with serial numbers 301 to 600 is completed as planned. This is because the main body member has been emptied in any of D and D. In this case, by adding the unreserved number of 10 and the empty part of the assembling process, the same condition as when all the temporary holding zones 2 and 3 are filled is used, and the ordering timing is advanced. .
Next, in step S6, the order position is set. First, in FIG. 8, the main body member present at the assembly position of the part e is Bγ696 corresponding to the serial number 696. The product corresponding to the serial number obtained by adding the serial number 696 to the number of unpending 10 pieces, the empty part of the assembly process, and the number of conveyances between arrival lead times (300 pieces) is October from the production sequence plan of FIG. It is a product of serial number 1011 planned to be produced on the 4th. The position where this product exists is set as the ordering position. The position where the product of serial number 1011 exists is a position that goes back 300 addresses from the part assembly position (address 111), and is the position of address 411. FIG. 8 shows that the position of the address 411 is set as the ordering position.
In subsequent step S8, parts are ordered based on the ordering position. In step S6, the position of the address 411 is set as the ordering position. Information on the parts to be assembled to the product existing at this position (the product with the serial number 1011 planned to be produced on October 4) is acquired from the product type / part type information storage unit 12. From FIG. 4, the part e is not assembled to the product produced using the body member Bγ1011 having the serial number 1011. Therefore, the part e to be used for a product having a serial number after this is ordered.
FIG. 10 shows a list of parts e ordered on October 2.
[0039]
As described above, the part e used from October 1st to October 4th can always be ordered at the ordering position of the address 411. Therefore, a predetermined number (10) of parts inventory can be secured at the assembly position of the parts e at any time, and a shortage can be prevented in advance.
[0040]
Specific examples of the present invention have been described in detail above, but these are merely examples and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes of the specific examples illustrated above.
In the present embodiment, the temporary holding band is provided in the production line. However, the present invention is not limited to this, and the present invention can be applied to a production line in which the temporary holding band is not provided.
In the present embodiment, the sensors are provided at the positions where the parts are assembled, but the present invention is not limited to this. The sensors can be provided at various positions as appropriate according to the conditions on the production line equipment, etc., and it is not necessary to provide the same number of parts assembling positions.
In the present embodiment, the parts a, b, c, d, and e are assembled one by one. However, the present invention is not limited to this, and any number of parts can be assembled. For example, when the product is an automobile and the part a is a tire, four parts a are assembled.
In the present embodiment, the standard conveyance speed when the production line is operated in a normal state is set to a certain “predetermined speed less than the maximum speed”. Further, the conveyance speed obtained by adding the number of parts in stock / one day to the standard conveyance speed is set as the upper limit “maximum speed” that can be increased to adjust the production pace. However, the present invention is not limited to these, and any transfer speed in the range from the lowest transfer speed that can operate on the physical function of the production line to the highest transfer speed will be Less than "predetermined speed" or "maximum speed".
In the present embodiment, the ordering position is set at a position advanced by the number of holdable times in the temporary holding band, but the present invention is not limited to this. It is possible to set the order position at an arbitrary fixed position according to the predicted maximum conveyance speed. Alternatively, it is possible to obtain an allowable number of stocks from the relationship of the storage space for parts, and to place the ordering position at a fixed position where the number of stocks can be secured.
In the present embodiment, the part e is ordered at each time when the main body member is conveyed to the ordering position. However, the present invention is not limited to this, and the number of parts used for a plurality of products may be obtained and ordered together according to the time interval at which the parts are delivered.
In addition, the technical elements described in the present specification or the drawings exhibit technical usefulness alone or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technology illustrated in the present specification or the drawings achieves a plurality of objects at the same time, and has technical utility by achieving one of the objects.
[Brief description of the drawings]
FIG. 1 is a diagram showing an outline of a production line.
FIG. 2 is a diagram showing a system configuration of a parts ordering apparatus.
FIG. 3 is a diagram showing product type / part type information and production order plan in a composite manner.
FIG. 4 is a diagram showing product type / part type information and production order plan in a composite manner.
FIG. 5 is a diagram showing a state of the production line at the end of the operation time on September 29.
6 is a diagram showing a state of the production line at the end of the operation time on September 30. FIG.
FIG. 7 is a diagram showing a state of the production line at the end of the operation time on October 1;
FIG. 8 is a diagram showing a state of the production line at the end of the operation time on October 2;
FIG. 9 is a diagram illustrating a procedure of part ordering processing.
FIG. 10 is a diagram showing a part order list.
[Explanation of symbols]
2: Production line
4: Body material production line,
6: assembly line,
12: Product type / part type information storage unit,
14: Production sequence plan storage unit,
16: Arrival lead time / transport number information storage unit between arrival lead times,
18: Standard transport speed information storage unit,
18: Order position setting adjustment number / order position setting adjustment time storage unit,
20: Means for calculating the number of parts in stock,
22: Body member grasping means,
24: Virtual order position conveying member product type specifying means,
26: Ordering means

Claims (2)

With the production of parts assembled products one after another successively assembled components to a member to be conveyed one after another to a position, encounters a production line to adjust the production pace by increasing or decreasing the transport speed at a maximum speed below the range Parts for production lines that have a temporary holding zone that adjusts the product production pace on the production line by temporarily holding the parts with the parts assembled between the rear end and the part assembly position. Equipment to order and
Production sequence plan storage means for storing the types of products produced one after another on the production line in association with the serial numbers of the production sequence;
Product / part type storage means for storing the part type used for the product in association with the product type;
A virtual ordering position conveying member type specifying means for specifying a type of product to be produced using a member that has been conveyed to a virtual ordering position each time production of the product virtually proceeds according to the production sequence plan;
Ordering means for ordering parts for a specified type of product ;
The ordering position is
(1) While the member conveyance speed is a predetermined speed less than the maximum speed, a position where a predetermined number of parts are stocked at the part assembly position ,
(2) When the member conveying speed is increased from the predetermined speed to the maximum speed, the parts ordered at a speed corresponding to the maximum conveying speed of the member are not assembled before the predetermined number of parts inventory is depleted. A position to arrive at the attachment position , and
(3) The serial number of the product to be produced using the member existing at the part assembly position, the number n of the production line temporarily reserved, and the part arrives at the part assembly position after ordering the part. The product corresponding to the serial number obtained by adding the number of members conveyed during the lead time is virtually present,
A part ordering apparatus characterized in that, when a part to be assembled at an assembly position is used for the product type specified by the virtual ordering position conveying member type specifying means, the ordering means orders the part. It is a production line that adjusts the production pace by assembling parts one after another to the parts that are transported one after another to the parts assembly position and producing products one after another, and increasing or decreasing the transport speed within the range of the maximum speed or less. Parts for production lines that have a temporary holding zone that adjusts the product production pace in the production line by temporarily holding the parts with the parts assembled between the rear end and the part assembly position Is a program for a computer to order and
  The computer performs the following processing:
  A process of referring to production sequence plan data that describes the types of products that are successively produced on the production line in association with serial numbers of the production sequence;
  A process of referring to product / part type data describing the part type used for the product in association with the product type;
  The serial number of the product to be produced using the members existing at the part assembly position, the number n of unholding in the temporary holding zone of the production line, and the lead time from when the part is ordered until the part arrives at the part assembly position Processing for calculating a position where the product corresponding to the serial number obtained by adding the number of members conveyed is virtually present as the ordering position;
  Each time production of a product virtually proceeds according to a production sequence plan, a process for specifying the type of product to be produced using a member that has been transported to a virtual ordering position;
  When a part to be assembled at the assembly position is used for the product type identified by the process for identifying the product type, the part is ordered.
  A program for ordering parts, characterized in that

Images