JPH0545377B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] This invention provides a method for automatically and timely producing processed parts in a production instruction device, particularly a production device equipped with an assembly line and a plurality of processing lines. The present invention relates to a production instruction device capable of leveling production on a processing line.

[Conventional technology] In various processing or assembly processes within a factory, it is necessary to accurately manage work in progress at each process, and it is known that such logistics management has a large impact on production efficiency. .

For example, a distribution control method known as the Kanban system in the automobile industry in recent years is useful for optimizing in-process inventory in a factory and simplifying its management.

The above-mentioned Kanban method aims to reduce the in-process inventory in the factory by requesting the delivery of the required amount of products or parts from the post-production process to the pre-production process in order, and it This is extremely useful in production processes where multiple process routes are gradually integrated.

However, although this type of kanban system is useful for managing required parts in subsequent processes, it does not have more detailed logistics information, so it is difficult to manage products or parts that are still in progress (hereinafter referred to as work-in-progress). There was a problem that no consideration was given to the order in which the products were supplied.

In particular, at the merging section where multiple processes are combined and sent to the subsequent process, the order of merging becomes a big problem in order to facilitate the equipment or work in the subsequent process, and the processing at this juncture makes it difficult for the subsequent process to proceed. Work can be leveled or batched, and the effects of leveling and batching can significantly improve overall production efficiency even in high-mix, high-volume production or high-mix, low-volume production.

On the other hand, there are cases where performing the same type of work in succession can significantly improve process efficiency, and in such cases it is necessary to serialize in-process work that has the same type of post-processing. In some cases, it is necessary to consider such lot formation at the confluence section.

For example, in the car assembly process, when painting the car body, painting the same color can be quickly done by continuous work, but when the color of the car body changes, the paint is applied in the painting process each time. It is understood that it requires a large amount of labor and time to set up, and that paint is wasted during such setup, which significantly reduces the efficiency of the painting process. Therefore, for such a painting process, it is preferable to continuously flow unfinished works of the same color.

FIG. 5 shows a schematic configuration of such a conventional production instruction device.

This production instruction device is an assembly line A consisting of multiple processes 10 to 16 as a multi-product mixed production line.
and at least two processing lines B ₁ and B ₂ for processing and supplying the same type of parts to one process 14 of the assembly line A.

A detection means 18 is provided near the assembly line A for detecting information on the type of semi-finished products that have passed through the assembly line A.
In the vicinity of B ₁ and B ₂ , the type information detected on the assembly line A is given to each processing line B ₁ and B ₂ , and production instructions for the processing lines B ₁ and B ₂ are given based on the type information. Instructing means 20-1 and 20-2 are provided.

This production instruction device is the assembly line A.
This is a production method in which parts of the same type are distributed and supplied from multiple processing lines B ₁ and B ₂ , and in general, parts of the same type are supplied to assembly line A in processing lines B ₁ and B ₂ . The system produces parts and supplies them as parts to other assembly lines or supply parts warehouses. The division of production among the processing lines at this time was determined by a monthly production plan, etc., which is normally carried out once a month.

[Problems to be solved by the invention] Conventional problems However, the order of products passing through assembly line A does not necessarily satisfy the condition of completely equalizing the production load between multiple processing lines B ₁ and B ₂ . This is not always the case, and there is often a problem that the production load balance between processing lines fluctuates greatly in a short period of time.

For this reason, parts could not be supplied to the assembly line A in time, and there were cases where the assembly line A was stopped due to missing parts.

In addition, among the products produced on assembly line A, there are products that do not require parts to be supplied from processing lines B ₁ and B ₂ , and information on products that do not require production of this type is stored on processing lines B ₁ and B 2 . In the past, when the output was output to B ₂ , the production of parts, etc. was switched at the discretion of the worker, etc., but even though there is a set delivery date for parts, etc., the production timing is determined by the worker. This meant relying on intuition, and depending on the order of the products flowing to assembly line A, there were cases where the timing for producing parts was missed and products were out of stock.

Furthermore, processing lines B ₁ and B ₂ are multi-stage continuous processes, and at the work instruction point, a large number of parts that have been processed in the previous process are kept as intermediate inventory, and parts that do not match the work instructions are transferred from the previous process to the subsequent process. When a part is transported to a process, it is moved to an intermediate inventory storage area, and instead, a part matching the work instruction is taken out from the intermediate inventory storage area and placed in the subsequent process.

This method requires a large intermediate inventory space, and has the problem of requiring a large number of man-hours to replace parts to be input into subsequent processes.

Purpose of the Invention The present invention has been made in view of the above-mentioned conventional problems, and it is an object of the present invention to manage and instruct the production timing of parts in a multi-product mixed production line using a control unit, thereby significantly improving the overall production progress efficiency. The purpose of the present invention is to provide an improved production instruction device that can perform the following tasks.

[Means and effects for solving the problems] The production instruction device according to the present invention includes an assembly line for assembling parts to various types of workpieces;
A main processing line that produces parts for various workpieces in synchronization with this assembly line and supplies them to the assembly line, and a main processing line that produces parts of the same type as this main processing line but for limited types of workpieces. A production instruction device for a multi-product mixed production line having a sub-processing line for supplying semi-finished products to an assembly line; The required parts production amount is calculated by accepting information from a parts information detection means for detecting processed parts information and each of the above-mentioned detection means, and from this parts production amount, the parts production amount of parts that can be produced on the sub-processing line is calculated. Calculate the required production volume of the main processing line to be produced on the main processing line, compare this required production volume of the main processing line with the initial production capacity of the main processing line, and calculate the required production volume of the main processing line from this initial production capacity. When the amount is small, the production of parts is instructed for the amount of difference, and when the required production amount of the main processing line is larger than the initial production capacity, the excess amount is carried over to the next production and production of the remaining amount is instructed, and the product information is The apparatus includes a control section that determines the production order on the main processing line in accordance with the order of product information from the detection means.

As described above, in order to appropriately divide the production between the main processing line and the sub-processing line, and also control the production order on the main processing line, the types of parts required on the assembly line and the parts supplied from the processing line are Even though the quantities are the same, the order of parts flowing through the assembly line and processing line is different, which eliminates the need for extra man-hours for adjusting the order of parts, and it is also possible to reduce intermediate inventory.

[Examples] Hereinafter, preferred embodiments of the present invention will be described based on the drawings.

FIG. 1 shows a schematic configuration of a production instruction device according to the present invention.

In the figure, this production instruction device has an assembly line in a multi-product mixed production line, and a plurality of processing lines that process and produce the same type of parts in synchronization with this assembly line. In the embodiment, the assembly line A is a production line that continuously produces a mixture of multiple types of automobiles, and the processing line is a bumper painting main line M that mainly produces color bumpers corresponding to each car model, and a parts production line. This line consists of a bumper painting subline S, which mainly produces products, etc.

As described above, the present invention is characterized by a detection means for detecting information on the type of semi-finished products that have passed through the assembly line, a detection means for detecting information on the processed parts that have passed through the processing line, and information from each of the above-mentioned detection means. and a control unit having a function of receiving the information and outputting a production sharing command to each processing line according to the production capacity of each of the plurality of processing lines, and controlling the processing order of each processing line in accordance with the production sharing command. This is what is happening.

That is, the assembly line A has multiple steps.
22 to 28, and a detection means 30 is provided near the assembly line A to catch information on the type of semi-finished products that have passed through one process 22. In addition, near the bumper painting main line M, one of the processes 47
Detection means 32 for detecting processed part information that has passed through
, a parts product information detection means 34 for detecting production information of parts products, etc., and a main line work instruction device 36 are installed, and a subline work instruction device 38 is installed in the bumper painting subline S.

Furthermore, a control section 40 stores, calculates, and processes each information from each of the detection means 30, 32, and 34, and outputs data to the work instruction devices 36 and 38 of each line.
is provided. The control unit 40 is composed of an input circuit for inputting various data, a display circuit for displaying the data, a memory circuit for storing various data, an arithmetic circuit, and an input/output circuit for inputting and outputting external information. Passing vehicle model information is input from the detection means 30 for detecting semi-finished product type information, passing bumper information is input from the processed parts information detection means 32, and parts product information is input from the parts product information detection means 34. .

The three types of detection means 30, 32, 34
When the amount of stored data of passing vehicle type information reaches a preset amount, the bumper painting main line M and the bumper painting subline S are stored.
Work instruction data is created according to the production capacity, and the information is sent to the main line work instruction device 36.
and is output to the subline work instruction device 38 as a production sharing command.

In the bumper painting main line M and the bumper painting subline S, colored bumpers are produced based on the output information from the control section 40, and are supplied to the bumper assembly process 26 of the assembly line A in units of lots.

FIG. 2 shows a program flowchart based on the embodiment.

The main program 42 always starts from step 100.
140, and other than that, the parts information detection means 34 shown in FIG. 3 a to c is performed.
a parts information input program 150 that stores information sent from the processing parts information detection means 32; a passing bumper input processing program 160 that stores the bumper information sent from the processed parts information detection means 32; and a vehicle model storage program that stores information sent from the semi-finished product type information detection means 30. It has a subprogram consisting of an information input processing program 170.

That is, in the condition determination process at step 100 in FIG. 2, it is determined whether a predetermined condition is satisfied, such as whether the vehicle model information has been changed in a certain number of lots, or whether information has not been continuously sent for a certain period of time. If the conditions are satisfied, the process proceeds to step 110.
In step 110, main line and subline production sharing processing, bumpers other than those to be produced on main line M and subline S are extracted from the stored vehicle model information, and each of the remaining vehicle model information is produced on bumper painting main line M. These are divided into those produced by the bumper painting subline S, and those produced by the bumper painting subline S.

Based on the information instructed to the bumper painting main line M obtained as a result, in the main line workload leveling process in step 120, if the main line share is less than the main line production capacity, data such as parts etc. is added. Or, conversely, if the production capacity is exceeded, processing is performed to hold the instruction data for the next time.

In the main line work order adjustment process in step 130, the bumper arrangement obtained by the passing bumper input processing program 44, which will be described later, is compared with the information created in the main line work load leveling process in step 120, and the main line work order adjustment process for bumper painting is performed. In order to minimize the sorting work on line M, the main line instruction information is sorted based on the bumper arrangement.

Then, in the work instruction output process of step 140, the main line work instruction information obtained up to the steps leading to the main line work instruction order adjustment process is sent to the main line work instruction device 36, and the subline work instruction information is sent to the subline work instruction Output to device 38.

Next, based on FIG. 3, the main program 4
The processing contents of the subprogram used in 2 will be explained.

In FIG. 3a, parts information input processing 150
Then, after receiving information from the parts product information detection means 34 installed in the painting main line M and confirming whether it is a kanban product or a repainted product, the information is stored for each instruction. . This parts information detection means 34 is transmitted at random timing because the operator inputs it manually when a repainted item occurs on the painting line or when a kanban item arrives. From then on, reading operations are performed periodically.

In the passing bumper input processing 160, a digital value is sent to the control unit 40 every time the bumper passes in front of the detection means 32 that detects information on a certain processed part in the pre-process of the painting line. Processing is performed to refer to it, convert it into vehicle type information, and store it.

In the vehicle type information input process 170, the vehicle type information (including color number, etc.) transmitted from the detection means 30 installed on the automobile assembly line A for detecting semi-finished product type information is received, classified, and stored.

Next, a specific example of this embodiment will be explained in which the vehicle types are X, Y, Z,
Vehicles with colors a, b, and c are produced on assembly line A, bumper painting line M produces all bumpers of all car models and the above color combinations, and bumper painting subline S produces products that correspond to Xa or Ya. The explanation will be based on an example in which production is divided so that only bumpers, that is, bumpers of the same color are produced.

The control unit 40 stores vehicle type (including color) information in a certain lot, and by this, the production share can be determined between the bumper painting main line M and the bumper painting subline S. By comparing the arrangement of bumpers with Since the order of the requested bumpers is different from the order of the bumpers flowing through the pre-process 48 of the painting line, it is possible to significantly reduce the extra man-hours required to adjust the order of each bumper one by one and send them to the top coating process 50 on the painting line. .

The specific processing contents will be explained below based on FIG. 4.

As shown in FIG. 4a, the process is started when the vehicle type information stored in the control section 40 reaches a certain lot (cutout lot).

In Figure 4b, vehicle models that are not produced on the painting line, such as purchased items or those with black base bumpers, are shown.
Yd is removed.

Further, as shown in FIG. 4c, information on the production of rear bumpers R in addition to front bumpers F also includes the rear bumper information R, and is displayed in units of the number of automobiles as units of the number of bumpers. In this embodiment, only the front bumper F is sufficient as the bumper for Za and Zc, and the rear bumper R for Za and the rear bumper R for Zc are unnecessary.

In Fig. 4b, it is determined whether the information created above is to be produced on the bumper painting main line M or the bumper painting subline S based on the set capacity of the main line M and the subline production vehicle type, and the bumper painting main line It is divided into those produced by M and subline S (production division).

In FIG. 4e, bumper painting is performed based on the bumper information of the main line M created in FIG. 4d, information input from the parts information detection means 34, and the production capacity of the bumper painting main line M. Information to be instructed to the main line M is created (main line load leveling).

Then, in FIG. 4f, the information created in FIG. The information is rearranged to obtain the final instruction information as shown in Figure 4g (main line order adjustment).

Note that when moving from f to g in Fig. 4, through the intermediate inventory space provided between the steps,
The parts that match the instructions, namely the bumper, are removed and replaced.

As explained above, according to this embodiment, when the supply capacity on the processing line exceeds the amount required on the assembly line, the production timing of parts with a deadline to be supplied to other than the assembly line can be changed.
Since the control unit 40 issues management instructions, there will be no shortage of items. In addition, major changes in the production order, which were previously required, can be kept to a minimum, leading to a significant reduction in man-hours and intermediate inventory.

[Effects of the Invention] As explained above, the present invention allows the sub-processing line to produce bumpers that can be produced according to the information obtained, and the remaining parts to be produced on the main processing line. Bumpers can be produced all at once. Therefore, compared to the conventional example in which the production of the same type of bumper is divided among the two, production can be carried out efficiently on both the main line and the sub-line. Therefore, the maximum number of production units can be set to a large value, and large changes in production can be accommodated. In addition, intermediate inventory can also be reduced.

[Brief explanation of the drawing]

Fig. 1 is a schematic configuration explanatory diagram of a production instruction device according to the present invention, Fig. 2 is a flowchart explanatory diagram of a control program in this embodiment, and Figs. 3 a, b, and c are used in the control program of Fig. 2. A flowchart explanatory diagram showing the contents of the subprogram to be executed,
FIGS. 4a to 4g are explanatory diagrams showing specific processing contents in this embodiment, and FIG. 5 is an explanatory diagram of a schematic configuration of a conventional production instruction apparatus. 30, 32, 34...detection means, 40...control unit, A...assembly line, M...machining main line, S...machining subline.

Claims (1)

[Claims] 1. An assembly line that assembles parts to various types of workpieces; A main processing line that produces parts for various types of workpieces in synchronization with this assembly line and supplies them to the assembly line; and a sub-processing line that produces parts for limited types of workpieces that are the same as the main processing line and supplies them to the assembly line. A product type detection means for detecting information on the type of semi-finished products that have passed through the assembly line, a parts information detection means for detecting information on the processed parts that have passed through each processing line, and a required part production amount by accepting information from each of the detection means. Calculate the required production volume of the main processing line that should be produced on the main processing line by subtracting the parts production volume of parts that can be produced on the sub-processing line from this parts production volume, and calculate the required production volume of this main processing line. Compare the initial production capacity of the main processing line, and when the required production volume of the main processing line is less than this initial production capacity, instruct parts production based on the amount of difference, and when the required production volume of the main processing line is greater than the initial production capacity. a control unit that carries over the excess amount to the next production and instructs production of the remaining amount, and determines the production order on the main processing line in accordance with the order of the product information from the product information detection means; A production instruction device characterized by: