JP2865507B2 - Mixed flow production system and operating method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mixed production system for producing a wide variety of products on a single production line and a method of operating the mixed production system, and more particularly to an automatic production instruction system for minimizing production line tact and improving production efficiency. The present invention relates to a mixed flow production system to be created and an operation method thereof.

[0002]

2. Description of the Related Art Generally, a product production line supplies parts necessary for assembling a product, assembles and manufactures the product, tests and inspects the performance of the product after the assembly is completed, and delivers a product that has passed the test and inspection to a packing area. It consists of a series of work steps before flowing. It is preferable to set up a production line for each product and perform production in the case of mass production, but in the case of high-mix low-volume production, the space and production facilities in the factory increase, and in the case of low-volume production, the idling of workers There is a problem that a lot of time is wasted on the space in the factory, production equipment and workers, and in order to solve this problem, the applicant of the present application
In other words, in order to flexibly respond to high-mix low-volume production and produce multiple types of products, workers in each process of the production line are automatically provided with necessary work instructions and information on defects that occurred in each upstream process of the production line. We have developed a mixed production system that automatically provides test reports to the workplace immediately before sending it to the packing site, and its operating method.

In such a mixed production system, the time required for workers and the like in each work place of a production line to simultaneously start and end a predetermined work process differs depending on each worker. Maximum time,
That is, the production line can move to the next operation step only after the tact time. It is said that the tact time is adjusted to move to the next process and produce at each tact time.In order to match this tact, the work assignment instruction at each work site is calculated by trial and error by manual calculation and the work instruction sheet Was produced, and production was performed according to the work instructions.

[0004]

However, in the production based on the work instructions created in this way, the takt is often inconsistent, so that some workers generate waste time, the production efficiency is poor, and the creation of the work instructions. Is time consuming and labor intensive. In addition, there is a problem that a work instruction sheet assigned work in response to a work change instruction from the production management system cannot be quickly created.

[0005] In view of the above problems, the present invention automatically creates a work instruction to improve production efficiency in accordance with the tact that minimizes the tact of the production line, and responds to a work change instruction from the production management system. It is an object of the present invention to provide a mixed production system for quickly creating work instructions assigned by work and an operation method thereof.

[0006]

FIG. 1 is a diagram showing the basic configuration of a mixed production system according to the present invention. The mixed production system of the present invention, which achieves the above object, comprises: an assembly site 1 for assembling parts delivered in the order of assembly on a single production line to assemble a plurality of types of products one by one; And a plurality of line terminals 3 provided in at least one of each of the assembling site 1 and the testing site 2, and a product or a pallet on which the product is mounted in order to match the flow of goods and information. A communication storage unit 4 for communicating and storing the production data for each product with the line terminal 3 when a pallet is conveyed to the production line, and a communication storage unit 4 in each of the assembling site 1 and the test site 2 Of the assembly site 1 and the test site 2 based on the read data. A line host control unit 5 for outputting the test results to the line terminal at the final test site for the products that pass the test, master file maintenance, work instruction management, progress management, schedule editing, A line host management terminal 6 for directly inputting and outputting data relating to history management and the like to and from the line host control unit 5.
Receives production instructions from the production management system connected to
Of work stored in the storage unit of the line host control unit 5
Date, model code, product name, production volume, work sequence and
And at least one of said operations
Schedule file with start time and each work process
Process with the product name, work start time and work name
Executed simultaneously by each worker based on a separate work file.
Before allocating work to minimize the tact time of each work process
The work instructions are prepared, and the work instructions are written to each line terminal.
3 for output .

In the mixed production system of the present invention, data on the content of a fault is input to a product to be replaced which has a fault .
Enter the data of the determined failure parts and Rutotomoni disorder, said La when repair the fault by replacing the fault parts
The failure content data and
And a failure terminal 7 for canceling the data of the failure component.

[0008] In the mixed production system of the present invention, the line host control unit 5 operates so as to minimize the tact time.
When preparing work instructions, to produce the specified product
Total man-hours, which is the sum of the man-hours required for each
Divide by the number of processes corresponding to the number of contractors
Work man-hours are calculated so that the average work man-hour is the upper limit.
In addition, the work is allocated to each worker,
Calculate each first subtotal of work man-hours, and
Divide by the rating (R), which is the work efficiency of each worker
To calculate the second subtotal, and calculate the total man-hours for each worker.
Is so approximately equal for each of the workers that
When calculating each first subtotal, do not assign
The remaining work was allocated to each of the workers, and
The work man-hours for each of the remaining work are calculated by the second subtotal.
To calculate the total man-hours for each worker. In the mixed production system of the present invention, the line host control unit 5 of the other embodiment is configured so that the tact is minimized.
When preparing work instructions, to produce the specified product
Total of all man-hours, which is the total number of man-hours required for each work
Is the sum of the ratings (R), which is the work efficiency of each worker
And multiply by each worker's rating.
Calculate the target distribution man-hour for each worker, and
Allocate each work to each worker so as to be the upper limit
To calculate the first subtotal of the number of man-hours for each worker.
Divide the first subtotal by the rating (R) to obtain each second subtotal.
Total work man-hours for each worker
Each of the first subtotals should be
The remaining amount not allocated to each worker when calculating
Work is allocated to each of the workers, and the remaining work allocated is
Add the man-hours for each of
The total work man-hour for each worker is calculated.

[0009] The method of operating the mixed production system of the present invention comprises:
Assemble multiple types of products one by one on a single production line
Test the performance and quality of the assembly
Each work to process each work process at the test site to be tested
To the assembly site and the test
Minimize the tact time of each of the above work steps executed simultaneously in the test site
Supply work instructions to the above workers
Method of operating a versatile production system, (1) the first step: each work to produce a predetermined product
The total number of man-hours required for each man-hour is reduced to the number of workers.
Divide by the corresponding number of processes to calculate the average man-hours for each worker
A first step to be issued, and (2) a second step: the average man-hour is set to be an upper limit.
In addition, the work is allocated to each worker,
A second step of calculating each first subtotal of operation man-hours; and (3) a third step: each of the first subtotals is performed by each of the workers.
Divide by the rating (R), which is efficiency, to get each second subtotal
A third step of calculating; (4) a fourth step: the total man-hours per worker is
Each of the first sub-elements is substantially equal for each worker.
The balance not allocated to each worker when calculating the total
Work is distributed to each worker, and the remaining
The work man-hour for each work is added to each of the second subtotals.
4th step of calculating the total man-hours for each worker by using
And the above steps having the following. Others of the present invention
The operation method of the mixed production system according to the embodiment is described above.
In the operation method of the mixed production system, (1) First stage: each operation for producing a predetermined product
The total work man-hours required for each worker
Divide by the sum of the efficiency ratings (R) and
The target distribution of each worker is multiplied by the worker's rating.
A first step of calculating the number of man-hours, and (2) a second stage: the target distribution man-hour is set to an upper limit.
In addition, the work is allocated to each worker,
A second step of calculating a respective first subtotal of man-hours, (3) Stage 3: the rating the respective first subtotal
Third step of calculating each second subtotal by dividing by (R)
If, (4) Stage 4: total work man-hours for each of the operator, the
Each of the first sub-elements is substantially equal for each worker.
The balance not allocated to each worker when calculating the total
Work is distributed to each worker, and the remaining
The work man-hour for each work is added to each of the second subtotals.
4th step of calculating the total man-hours for each worker by using
And the above steps having the following.

[0010]

In the mixed production system of the present invention, the line host control unit 5 stores the data written in the communication storage unit 4 transported to the assembly site 1 and the test site 2 into the line terminal 3.
Via the assembly line 1 based on the read data.
In addition, a work instruction for each worker in the test site 2 is output via the line terminal 3 by a display device or the like of the line terminal 3. However, in the mixed production system of the present invention, the line host control unit 5
Receiving a production instruction from a production management system connected to
Opening work previously stored in the storage unit of the line host control unit 5
First day, model code, product name, production volume, work sequence
And a predetermined work process comprising at least one of the above works
Schedule file and start time of each work
A process that describes the product name, work start time, and work name for each product
Executed simultaneously by each worker based on the work file
Creates the work instructions with the work distribution that minimizes the tact of each work process, ie, line balance loss
Then, the work instruction is automatically output via each line terminal 3.

[0011]

FIG. 2 is a diagram showing an embodiment of the mixed production system of the present invention. In the figure, M1 to M6 are assembly sites for assembling products, and T1 to T14 are test sites for testing and inspecting equipment after assembly is completed. Here, the equipment is the first test site T where all the parts that make up the product are assembled.
It means an assembly of parts until the assembly is completed until it is transferred to 1. At the assembly sites M1 to M6, the equipments 1 to 6 are assembled respectively. In the assembly sites M1 to M6, necessary parts according to the types of products are temporarily stored in a component supply station (not shown), and are delivered to the assembly sites M1 to M6 by a carrier in the order of assembly. Some assembly sites are not used due to the number of parts. For example, assembling sites M1 to M
When the assembly is completed by up to 4, the assembly sites M5 and M6 are not used. In this embodiment, a communication storage unit, that is, an ID card (not shown), which is a data carrier, is mounted on a pallet on which a product is placed, and information necessary for producing the product via a line terminal is transmitted to the pallet using the ID card. Transmitting and receiving with the host control unit.

FIG. 3 is a diagram showing hardware between the ID card and the line host control unit. In the figure, reference numeral 11 denotes an optical ID unit, which is an ID card according to the present invention. The ID card 11 is mounted on a product or a pallet on which the product is mounted, while an optical terminal 12 is installed at each assembly site and each test site.
When a pallet is conveyed, it is detected by a photoelectric switch or the like provided at each assembly site or each test site, and the sequencer 1
4 stops an unillustrated conveyor and starts each operation of assembling or testing. Before that, the ID card 11 and the optical terminal 12 communicate with each other to read and write data. The reading and writing of these data are performed by the line host controller 1.
The transmission and reception signals of the optical terminal 12 are amplified by the control unit 13 under the control of the control unit 6, and the control unit 13 communicates with the line terminal 15 via the sequencer 14 or directly with the line terminal 15.
It is connected by the interface of S-232C.

Referring back to FIG. 2, an embodiment of the mixed production system of the present invention will be described in detail. The equipment terminal, which is a line terminal in the assembly site M1, transmits a product code corresponding to the model to the line host control unit by keyboard input or bar code reading, and the line host control unit stores the product stored therein. Code, management No. And step NO. , Data to be described later, such as a work start time, a work end time, and a test pattern, are written to the ID card via the device-in-process terminal, and the C provided in the device-in-process terminal.
An assembly work instruction is output to an RT monitor or a printer to inform the worker. The worker at the assembly site M1 starts to drive a conveying means, that is, a conveyor (not shown) for sending the assembled product to M2 in accordance with the work instruction.

In each of the assembling sites M2 to M6, each of the equipment terminals, which is a line terminal device, uses a pallet ID card sequentially transported to each work site to produce a product code and a management code.
O. And the like, and reads the model, number, edition number, and date of manufacture of each component of the equipment from, for example, a bar code attached to each part, and transmits those data to the line host control unit, and sends the data to the line host. The control unit outputs the assembly work instruction corresponding to each of the assembly sites M2 to M6 stored in the control unit to a CRT monitor or a printer provided in each equipment terminal to notify the worker. In this way, the operator starts driving the conveyor means (not shown) that sequentially sends the equipments 1 to 6 being assembled to the next assembly site, and finally transfers the equipment 6 to the test site T1.

The entrance examination terminal, which is a line terminal at the test site T1, receives the product code, management No. from the ID card of the transported pallet. And transmits the model, number, edition, and date of manufacture of each component of the product to the line host control unit by reading a barcode attached to each component, for example. After confirming whether or not there is a mounting leak in 6, for example, a work instruction indicating that there is a mounting leak or the like is output to a CRT monitor or a printer provided in the entrance examination terminal to notify the worker. Further, the entrance examination terminal stores the process number in the test site T1 on the ID card. ,
Write the data of the determination result indicating the work start time, the work end time, and the presence or absence of a failure. Next, the worker puts the equipment 6 on the test site T
The driving of the conveying means, that is, the conveyor (not shown) for feeding the sheet 2 is started.

The line terminal at the test site T2 uses the ID card of the transported pallet to produce a product code,
O. To the line host controller, the line host controller checks the soft keep, that is, whether or not to write the test program on the hard disk of the product, and outputs the test program to the CRT monitor or printer provided in the line terminal for work. If there is no soft keep, the worker starts transporting to the next test station T3 as it is, and if there is soft keep, the worker temporarily pools it on the soft keep shelf, writes the test program on the hard disk of the product, and then writes it to the next stage. To the test site T3.

The line terminal at the test site T3 uses the transferred pallet ID card to produce
O. Is read to the line host control unit, and the line host control unit checks whether the equipment 6 should be retired (returned to the repairing process as returned goods) and checks the CRT monitor or the printer provided in the line terminal. To inform the worker, and when the worker is confirmed to be retired, the equipment 6 is placed in the retirement yard, and when the worker is not confirmed to be retired, the setting instruction of the setting conditions of the high-temperature aging / low-temperature aging device is confirmed. In accordance with the setting instruction, the setting of the aging device, for example, the aging time for the set voltage during aging such as 2 hours at the voltage VL (less than 5 V), 12 hours at the voltage VH (more than 5 V), and the size of the equipment, especially The number of stages occupied by the aging device according to the height is set, and the driving of the transfer means in the high-temperature aging is started toward the next test site T4.

The number of occupied stages is six in both the high-temperature aging device and the normal temperature aging device in the subsequent stage.
Two or three stages are occupied by one equipment depending on the height of the equipment. In addition, the high-temperature aging device is provided with a transport device for the outward route and the return route, and the room-temperature aging device is provided with a transport device for only the outward route. Here, retirement was conducted at test sites T4, T5, T in addition to test site T3.
7 and T14.

Test site T on the outbound path of the high-temperature aging device
The line terminal at 4 is the ID of the transported pallet.
From the card to the product code, management No. Is read to the line host control unit, and the line host control unit outputs to a CRT monitor or a printer provided in the line terminal to notify whether or not the equipment 6 is capable of automatic voltage adjustment. When it is confirmed that the automatic voltage is variable, the voltage setting is manually changed when it is confirmed that the automatic voltage is not variable, and the return path of the high-temperature aging apparatus is transported in the high-temperature aging toward the next-stage test site T5. Start driving the means.

Next, the line terminal at the test site T5, which has left the return route of the high-temperature aging device, uses the ID card of the conveyed pallet to obtain the product code, management NO. Is sent to the line host control unit, and the line host control unit outputs the aging time for the aging device at room temperature, that is, the room temperature, to the CRT monitor or the printer provided in the line terminal and the number of occupied stages as described above. Then, the operator sets the aging time and the number of occupied stages of the room temperature aging apparatus, and starts driving the transport means in the room temperature aging apparatus.

After being conveyed to the test site T10 after the normal temperature aging, the line terminal at the test site T10 uses the ID card of the conveyed pallet to produce a product code and a management code.
O. Is sent to the line host controller, and the line host controller outputs the result to a CRT monitor or a printer provided in the line terminal to inform the operator whether the product is soft-keeping, that is, whether the basic software (OS) is written. Informing the operator, when there is soft keeping, the writing process is executed, and when there is no soft keeping, the worker starts driving the transporting means to the packing place so as to start transporting to the testing place T14 as it is.

Next, the line terminal at the test site T14 uses the ID card of the transported pallet to produce a product code, a management NO. Is transmitted to the line host controller, and the line host controller causes the printer of the line terminal of the test site T14 to issue a test report. In addition, a trial warehouse entry process, that is, a notification of an assembly inspection completion report is transmitted from the line host control unit to the production management system. Further, the line host control unit communicates with the packing site host control unit in the packing site via the LAN, and prepares the cardboard necessary for packing using a printer or a CRT monitor of the management terminal of the packing site host control unit. Notify the worker of the packing work instruction to the operator. On the other hand, the line terminal of the test site T14 stores the process number of the test site T14 on the ID card. Then, data of the determination result indicating the work start time, the work end time, and the presence or absence of a failure is written. Finally, the operator starts to drive a conveying means, that is, a conveyor (not shown) for sending the product to the packing place.

Further, a faulty terminal is provided near the work site for repairing the fault, and data of fault content for the product to be replaced which has a fault is input via the faulty terminal, and the faulty component determined to be faulty is input. When the data is input and the faulty component is replaced and the fault is repaired, various operations such as canceling and inputting the data of the faulty component are executed to perform quality control.
The line host management terminal (not shown) transmits data relating to master file maintenance, work instruction management, progress management, schedule editing, history management, and the like to a line host control unit (not shown) on the same floor as the production line. Use when inputting / outputting directly to). Further, the line host control unit outputs a work instruction to minimize the tact via each line terminal.

FIG. 4 is a diagram showing a format of an ID card. As shown in the figure, the ID card used in the embodiment has a storage capacity of 2 Kbytes, and a memory of 32 bytes (here, 4 bits of 1 byte) is allocated to each of the 22 addresses. Product code of product, management No. , Failure, line-out flag, line-in, VH / VL selection, line-out process, pallet return, re-input flag, NO. 1 keep flag, NO. The 2 keep flags, VN, VL, VH automatic power supply variable, and address 2 store data related to line control such as high-temperature VH aging time, high-temperature VL aging time, normal-temperature aging time, switching of stages, and spare. Addresses 3 to 8 are processes from loading machine 1 (assembly site M1) to loading device 6 (assembly site M6), and addresses 9 to 20 are processes from entrance examination (test site T1) to trial (test site T14). NO. , Start time, determination result, end time, and spare data.

Here, the contents of the memory will be supplementarily described below. “Fixed” indicates the head address of the memory, and is set to 0. Indicates the model and unit of the product, respectively, indicates the presence or absence of a failure, and indicates whether there is a missing part or an abnormal test result.The line-out flag indicates how the product is assembled or tested until the first retirement after failure is detected. The line-in is data for indicating re-injection, indicating whether or not retirement has been performed and in which step a retirement instruction has been issued. For example, 00 indicates no retirement, and 01 indicates that there is a retirement instruction in step 1. The VH / VL selection is for indicating whether VH or VL is set in the automatic power supply variable device provided in the test site T4, the line-out process indicates a retired process, and the pallet return indicates the top of the pallet. When returning to the process, it is data indicating whether to return through the high-temperature aging device in the course of passing or bypassing, the re-input flag indicates whether the product is a re-input product,
NO. The 1 keep flag indicates whether or not to load a test program. The 2 keep flag indicates whether or not to load an OS (basic program) on the hard disk.
VN, VL, VH automatic power supply variation indicates whether or not the product has a function of performing automatic voltage variation.

The high-temperature VH aging time, the high-temperature VL aging time, and the normal-temperature aging time at the address 2 indicate, for example, data 1230 and are set for 12 hours and 30 minutes.
This means setting to two or three stages. Address 3
No. to 22 in step NO. Indicates data indicating the assembly sites M1 to M6 or the test sites T1 to T14, the start time and the end time are respectively written as days, hours, minutes, and seconds, and the determination result indicates the presence or absence of a failure result.

As described above, the data for each product is stored in the ID card, and is read and written at each assembly site and test site as the equipment is transported on the production line. Based on these data, the up-to-date ( It is possible to give the latest (up-to-date) and accurate work instructions and to have shared data through communication with the quality information system and the production management system, thereby enabling support for quality management and production management.

The operation of the present invention will be described below, but before that, various files stored on the disk in the line host control unit will be described. These files include work content, workers, time change and standard flow order files that can be maintained by the host management terminal created in advance, and disk in the line host control unit such as member management and equipment jigs and tools related to loading and unloading. Files to be loaded into the system, files related to work instructions such as the number of products input from the production management system, and schedule files for improving the production efficiency of the mixed production line finally created by the mixed production system of the present invention. And process-specific files.

FIG. 5 is a diagram showing a specific example of a work content file stored in the line host control unit. The model code 10451 corresponds to the name α of the device to be produced, and the model code 74329 corresponds to the name β of the device to be produced. The names X _{1 to} X ₂₁ and the device names β are classified as work names X _{22 to} X ₂₄ , respectively.
For each work name, data such as work contents, assembled parts, setup time, work man-hours, work sequence and notes (not shown) are stored in the disk of the line host control unit. Also,
The assembled part stores data of the name of the part, the source of the part and the quantity of the part, and the setup time stores the data of the time required for preparation and the time required for clearing. In the work order, for example, numerical data of 1 to 18 in the order of assembling efficiently among the work names X _{1 to} X ₂₁ is stored for the device name α. If the same numerical value is two or more, those work contents may be performed in any order. The unit of the setup time and the man-hour is based on seconds or minutes. Notes, for example for work name X ₅ "bracket to stop Preface to the left", for "work name X ₁₅ is the description of the work on the necessary precautions, such as" that the upper cover the gap defunct " Data is stored. The work content file is such a database.

FIG. 6 is a diagram showing a specific example of a file stored in the line host control unit.
(B) is a diagram showing a time change, (C) is a diagram showing each file in the standard delivery order. FIG. 6A shows a file related to the worker, and the ID (identification) No. of the worker. , Name and rating are stored. FIG. 6 (B) is a file relating to a time change, and data of a time zone with good work efficiency is stored. FIG. 6 (C) is a file in a standard delivery order. , The priority of production is determined in advance for each model code, and numerical data in the order indicating the priority is stored. The models within the same number may be produced in any order.

FIG. 7 is a diagram showing a specific example of a file stored in the line host control unit.
(B) is a diagram showing components, and (C) is a diagram showing each file of a production instruction from the production management system. FIG. 7A is a file of equipment jigs, which stores data on the current stock quantity of jigs and tools used in the test process, and this quantity is subtracted when it is put into the production line and collected from the production line. When added. FIG. 7B shows a component file, and FIG. 7B shows a component file, which is either the part name or the equipment jig for the apparatus α, and the quantity of the part or the equipment jig. Is shown. The table shows which equipment jigs and tools are used for which equipment. FIG.
(C) is a file for a production instruction transmitted from the production management system, and shows data relating to the production instruction, and stores data on the production start date, model code, device name, number of units, and scheduled completion date. Is done.

FIG. 8 shows a file stored in the line host control unit.
It is a figure which shows the specific example of a file, (A) is an operation | work by process,
(B) shows each file of the in-process sequence (schedule).
FIG. FIG. 8A is a file of the work by process.
Each process M₁, M_Two, M_ThreeAbout equipment name, production
Number, work start date and time, tact pitch (unit is
Seconds or minutes) and the data of the work content are stored.
The content is the work name X₁~ X _{twenty one}Is stored. What
The unit of time of the tact pitch is seconds or minutes. Figure
8 (B) is a file of a work-in-progress order (schedule).
Start date, model code, production stand for each device
Number, work-in-progress sequence which is the order of production, and first process M₁Work
Each data of the work start time is stored.

As described above, files of work contents, workers, time change, and standard flow sequence are created in advance, and members (product components) relating to loading and unloading and files of equipment jigs and tools are loaded. After inputting the production instruction from the production management system, execute the following steps,
Finally, a work file for each process and a schedule file are created.

FIG. 9 is a flow chart for creating a work instruction sheet that provides an optimum line balance. The number following S in the figure indicates a step number. Files of work contents, workers, time change and standard flow order which can be maintained by the host management terminal, and files such as components and equipment jigs and tools are previously loaded on a disk in the line host control unit. Also, it receives a production instruction such as the number of products from the production management system. The contents of these files are described below. (Step S1): It is determined whether or not the surface alignment for checking that all the assembled parts have been completed is completed. If YES, the process proceeds to Step S3, and if NO, the process proceeds to Step S2. The determination of the completion of the alignment is performed by determining the data of each quantity of the parts constituting the product written in the product component file (stored in the disk in the line host control unit) for the product to be produced in the next process, and managing the members. The comparison is made with the data of the stock quantity of each part stored in the disk in the line host control unit, and the stock quantity is compared with the quantity of each part constituting the product required in the next process. Stock quantity data is always updated at the time of entry and exit.

(Step S2): It is determined whether or not to continue because of an alignment error. If YES, the process shifts to the step S3. If NO, the process returns to the step S1. In this case, the operator judges the CRT of the host management terminal while looking at the CRT, and instructs to continue the production as it is when a part that is insufficient in the surface alignment can be attached later. (Step S3): The production instruction from the production management system is read. (Step S4): It is determined whether or not the file of the production instruction is completed. If YES, the process proceeds to step S7, and NO
If so, the process proceeds to step S5. (Step S5): The standard flow order is read based on the model code. (Step S6): Create (write) a schedule file that describes the work start date, model code, device name, number of production units, work sequence, and work start time of a predetermined work process.
I do. (Step S7): The schedule files are sorted in the flowing order. Steps S3 to S6 are stages in which a standard flow order is set in response to an instruction from the production system.

FIG. 10 is a flowchart following FIG.
You. (Step S11): Total work number n, total work man-hour X minutes,
One man-hour X_nMin, number of steps m, in the first method
(Total number of work steps / number of steps = X / m) = A_i1= A_i2= ... = A
_imMinutes and in the second method A_i1= Total man-hours x R₁
/ (R₁+ R_Two+ ... + R_m) Min, A_i2= Total man-hours x R
_Two/ (R₁+ R_Two+ ... + R_m) Minute,…, A _im= All workers
Number x R_m/ (R₁+ R_Two+ ... + R_m) Minutes. For each process
Man-hour A_mMinutes, man-hours for fictitious process A_FMin, rating R
And variables L and J are set. X, A_im,
A_m, A_F, L are set to 0, J is set to
It is one. (Step S12): J is compared with m, and J is greater than m
If so, the process proceeds to step S16 to determine whether J is equal to m or not.
Moves to step S13 when J is smaller than m. (Step S13): A_JAnd A_imAnd compare A_JIs A_im
If it is larger, the process proceeds to step S15, and A_JIs A_im
Is equal to or A_JIs A_imIf smaller than step
Move to S14. (Step S14): Add 1 to L and update L data
I do. A_JTo X_LAnd add A_JUpdate the data of. (Step S15): 1 is added to J and the data storage unit of J is added.
To update.

(Step S16): Variable L and total number of operations n
When L is larger than n, the process proceeds to step S21, and when L is equal to n or L is smaller than n, the process proceeds to step S17. (Step S17): 1 is added to L to update L data. Adding X _l to A _F updates the data storage unit of A _F.

FIG. 11 is a flowchart following FIG.
You. Man-hour A for fictitious process_FElement of X _l, X_{l + 1,}…_,X_n
To optimize production line tact,
Loss due to variation in working time in each process of
In other words, minimize the line balance loss as follows.
U. Next, man-hour A for the fictitious process_FThe number of elements n ′ of n
, Calculate the following equation (1), and rate
A total man-hour Y after the multiplication is obtained. Y = A₁× 100 / R₁+ A_Two× 100 / R_Two+ ... + A
_m× 100 / R_m+ X_l+ X_{l + 1}+ ... + X_n.. (1) Average value y = Y / m (2)
It is calculated by the above equation (3). ΔA₁= Y- (A₁× 100 / R₁+ X_l× Z₁₁+ X_{l + 1}× Z₁₂+ ... + X_n× Z_{1n '}), ΔA_Two= Y- (A_Two× 100 / R_Two+ X_l× Z_{twenty one}+ X_{l + 1}× Z_{twenty two}+ ... + X_n× Z_{2n '}), ......, ΔA_m= Y- (A_m× 100 / R_m+ X_l× Z_m1+ X_{l + 1}× Z_m2+ ... + X_n× Z_{mn '}) (3) The following flow is executed below.

(Step S21): Determine line balance
Variable O to determine_pSet the average value y obtained in advance to
You. (Step S22): Matrix Z₁₁To Z_{mn '}All
Set to 0. Where Z₁₁To Z_{mn '}Is a variable of 0 or 1
is there. (Step S23): Variable Z_LOOP1,1At_LOOP1But
From 1 to m, the variable Z _LOOP2,2At_LOOP2Is from 1
up to m, ..., variable Z_{LOOPn ', n'}At_{LOOP n '}Is one
From step S24 to step S25
And step S26, and return to step S22. (Step S24): ΔA₁From ΔA_mIs calculated. (Step S25): ΔA₁From ΔA_mThe absolute minimum of
Value and ΔA₁From ΔA_mThe value obtained by adding the absolute value of the maximum value of
Is set as Loss data. (Step S26): Loss value and O_pCompare the values of
And the value of Loss is O_pEqual to the value of or O_pThe value of the
If it is smaller, the process proceeds to step S27 and the value of Loss
Is O_pIf the value is larger than the value, the process returns to step S22.

(Step S27): Variable O_pLost to
Set the value of. (Step S28):_LOOP1Any of 1 to m in
Variable Z _op1To remember_LOOP21 in
From the variable z to the variable Z_op2To memorize ...
…,_{LOOPn '}Change any value obtained from 1 to m in
Number Z_{opn '}To memorize. As a result, Z₁₁From
Z_{mn '}Is set to 1 or not, that is, what
It is determined which operation is to be performed in these steps. In other words
Matrix Z described above₁₁To Z_{mn '}Which is 1 and what
It is determined whether this is zero.

(Step S29): For each work process, a work file for each process indicating which device is to be started and at what date and at what time, and which work is to be executed is created.

FIG. 12 shows a first method of calculating the optimal line balance.
It is a figure which shows the specific example of a method. This is the number of operations of 21 (n =
21) In three steps (m = 3) M1, M2, M3
Each rating R₁= 110, R_Two= 80, R
_Three= 95 line balance when workers work
The following is an example of calculation for minimizing the load. Each man-hour X_1,X_2,… _,
X_{twenty one}Is as shown, X₁To X₆Sum A up to₁
Becomes 62 and X₇Is added and becomes 80 (all workers
Number / number of steps) = A_im= 213/3 = greater than 71
And X₇The following is the work process of the next worker. Next, X₇
To X₉Sum A up to_TwoBecomes 49 and X_TenAdd more
Becomes 72 and A_im= 71, so X_TenAfter
Worker's work process. Next, X_TenTo X₁₄For up to
Sum A_ThreeBecomes 63 and X₁₅Is added to become 72 and A
_im= 71, so X₁₅After X_{twenty one}Up to three people
Assign to contractors. Multiply the rating for each operation
The values obtained are 57, 62, and 67, respectively, as shown in the figure.
The work distribution that minimizes the line ban loss is shown in the figure.
Thus, each work process is 75 and the line van loss is 0.
It turns out that it is.

FIG. 13 shows a second method of calculating the optimal line balance.
It is a figure which shows the specific example of a method. This is the number of operations of 21 (n =
21) In three steps (m = 3) M1, M2, M3
Each rating R₁= 110, R_Two= 80, R
_Three= 95 line balance when workers work
The following is an example of calculation for minimizing the load. Each man-hour X_1,X_2,… _,
X_{twenty one}Is as shown in the figure.
A certain total man-hour is X = 213. In this second method
In addition, the sum of all man-hours
Divide by total and multiply by each worker's rating
When the target distribution man-hours of the contractors are obtained, the target distribution
Number A_im(M = 1 to 3) is A_i1= 213 × 110 / (110 + 80 + 95) = 8
2.2 A_i2= 213 × 80 / (110 + 80 + 95) = 5
9.8 A_i3= 213 × 95 / (110 + 80 + 95) = 71. On the other hand, X₁To X₇Sum A up to₁Is 80
Multiplied by the rating gives 80 × 100/1
10 = 72.7. X₈After that, the next worker
X₈To X_TenSum A up to_TwoIs 54
Multiplied by the rating gives 54 × 100/8
0 = 67.5. X₁₁The following is the work process of the next worker
Then X₁₁To X₁₉Sum A up to_ThreeBecomes 70,
Multiplying this by the rating gives 70 × 100/95 =
73.7. Finally, reduce the remaining man-hours to three workers
Allocate. Here, X₂₀= 3, X _{twenty one}= 6 each
Re M₁, M_TwoDistributed to A₁'= 72.7 + 3 = 75.
7, A_Two'= 67.5 + 6 = 73.5, A_Three'= 73.
Ask for 7. Therefore, to minimize line bang loss
As shown in the figure, the work distribution for each work process is 7
5.7, 73.5, 73.7
It turns out that it is small.

FIG. 14 is a diagram showing a specific example of the CRT screen of the work instruction sheet. In the figure, the work content is changed to the time t by adjusting the display screen of the CRT in the equipment process 1 and the equipment terminal 1 to the tact.
The process of changing every 0, t1, t2,..., T5 is shown. Although not shown, the work contents of the mounting process 2 follow the work of the mounting process 1 and the work contents of the mounting process 3 follow the work of the mounting process 2 and are each displayed with a delay of one tact time. . The figure shows an example of assembling the equipment names α and β in order, and notes are displayed in addition to the work contents. If there is no work contents, a message about preparation or a notice of work end is displayed.

FIG. 15 is a diagram showing a specific example of a CRT screen for trouble information, in which (A) shows an example of inputting trouble data.
(B) is a diagram showing an example of inputting an error code of a failure phenomenon. In FIG. 15A, the operator inputs 00 when the test process is the basic process, 01 when the test process is the aging process, and 02 when the test process is the final process from the keyboard of the faulty terminal while watching the display screen. Similarly, the corresponding code number is input for the temperature condition, the voltage condition, and the impact. In FIG. 15B, the operator similarly inputs an error code of the failure phenomenon from the keyboard of the failure terminal while looking at the display screen.

FIG. 16 is a diagram showing a specific example of a CRT screen of trouble information, in which (A) shows a trouble product in the product.
(B) is a diagram showing a parts list of a product after replacing a defective product with a good product. (A) of FIG. An example in which the 3.5-inch floppy disk having the device unit name of No. 6 is determined to be defective is displayed. 06 data is deleted from the disk of the line host control unit. (B) of FIG. 06 shows a display screen when a new equipment unit is replaced and repair is completed, and the version number of the replaced equipment unit and the machine number are input from the keyboard of the faulty terminal.

[0047]

As described above, according to the mixed production system and the operation method of the present invention, the tact balance loss of the production line is minimized in response to a work change instruction from the production management system, thereby improving production efficiency. A system for quickly and automatically creating a work instruction, that is, a schedule file and a process-specific work file can be provided.

[Brief description of the drawings]

FIG. 1 is a basic configuration diagram of a mixed production system of the present invention.

FIG. 2 is a diagram showing an embodiment of the mixed production system of the present invention.

FIG. 3 is a diagram illustrating hardware between an ID card and a line host control unit.

FIG. 4 is a diagram showing a format of an ID card.

FIG. 5 is a diagram showing a specific example of a work content file stored in a line host control unit.

FIGS. 6A and 6B are diagrams showing specific examples of files stored in a line host control unit, wherein FIG. 6A shows a worker, FIG. 6B shows a time change, and FIG. is there.

7A and 7B are diagrams showing specific examples of files stored in a line host control unit, wherein FIG. 7A shows equipment jigs and tools, FIG. 7B shows components, and FIG. 7C shows production instructions from a production management system. It is a figure showing a file.

FIGS. 8A and 8B are diagrams showing specific examples of files stored in the line host control unit, wherein FIG. 8A shows work by process, and FIG. 8B shows files in process (schedule);

FIG. 9 is a flowchart for creating a work instruction sheet that provides an optimal line balance.

FIG. 10 is a flowchart following FIG. 9;

FIG. 11 is a flowchart following FIG. 10;

FIG. 12 is a diagram showing a specific example of a first method of calculating an optimal line balance.

FIG. 13 is a diagram showing a specific example of a second method of calculating an optimal line balance.

FIG. 14 is a diagram showing a specific example of a CRT screen of a work instruction sheet.

FIG. 14 is a diagram showing a specific example of a CRT screen of fault information, where (A) shows an example of inputting fault data, and (B)
Shows an example of inputting an error code of a failure phenomenon.

16A and 16B are diagrams showing a specific example of a CRT screen of trouble information, in which FIG. 16A shows a trouble product in the product, and FIG. 16B shows a parts list of the product after the trouble product has been replaced with a good product. FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Assembly place 2 ... Test place 3 ... Line terminal 4 ... Communication storage unit 5 ... Line host control part 6 ... Host management terminal 7 ... Faulty terminal

────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yasuaki Ishiyama 98-2 Unoki-nu, Unoki-cho, Kawakita-gun, Ishikawa Pref. JP-A-2-71962 (JP, A) JP-A-2-65958 (JP, A) JP-A-6-139251 (JP, A) JP-A-5-50369 (JP, A) (58) Fields investigated (Int) .Cl. ⁶ , DB name) B23Q 41/08 G05B 13/02 B23P 21/00 G06F 19/00

Claims (6)

(57) [Claims] 1. An assembly shop (1) for assembling parts delivered in the order of assembly on a single production line and assembling a plurality of types of products one by one, and testing and inspecting the performance and quality of the products after the completion of assembly. A test site (2), a plurality of line terminals (3) provided in at least one of each of the assembly site (1) and the test site (2), and a product or product placed thereon for matching the flow of information with an object. A communication storage unit (4) which is added to a pallet and communicates and stores the production data for each product with the line terminal (3) when the pallet is conveyed to the production line; The data stored in the communication storage unit (4) is read via the line terminal (3) at each work place of the test site (2), and the assembly site (1) and the front are read based on the read data. A work instruction for each worker at the test site (2) is output to the line terminal (3), and a test report is output to the line terminal (3) at the final test site for a product that has passed the test. A line host control unit (5) and a line host management terminal for directly inputting and outputting data relating to master file maintenance, work instruction management, progress management, schedule editing, history management, etc., to the line host control unit (5) (6) In the mixed production system, the line host control unit (5) is configured to control the line host control.
Receiving production instructions from the production management system connected to the
Opening work previously stored in the storage unit of the line host control unit
First day, model code, product name, production volume, work sequence
And a predetermined work process comprising at least one of the above works
Schedule file and start time of each work
A process that describes the product name, work start time, and work name for each product
Executed simultaneously by each worker based on the work file
Work distribution to minimize the tact of each work process
Create the work instructions and copy the work instructions to each of the lines
A mixed production system for outputting via a terminal (3) . 2. The line flow production system according to claim 1, wherein
To strike the control unit, for the products to be replaced with the failed enter the data of the determined failure parts and failure inputs the data of the fault contents, when repair the fault by replacing the fault parts Was input to the line host controller.
Versatile production system according to claim 1, further comprising the failure contents of the data and the cancel the failed part of the data failures terminal (7). 3. The line host control section (5),
Create the work instructions so that tact is minimized
When the total of the number of steps required for each work to produce a predetermined product
Total work man-hours by the number of processes equivalent to the number of workers
Calculate the average man-hours of each worker by dividing, and perform each work beforehand so that the average man-hours is the upper limit.
Allocated to each worker, the first small of the man-hour for each worker
The first subtotal is calculated as the rate of work of each worker.
(R) to calculate each second subtotal, and calculate the total man-hours per worker for each worker.
When calculating each of the first subtotals so that they are substantially equal,
The remaining work not allocated to each worker is
To each of the remaining tasks allocated to the workers.
Work man-hours to each of the second subtotals, and
The mixed production system according to claim 1 , wherein a total man-hour is calculated . 4. The line host control section (5) is
Create the work instructions so that tact is minimized
When the total of the number of steps required for each work to produce a predetermined product
The total of the total man-hours is the work efficiency of each worker.
Divide by the total rating (R), and
To calculate the target allocation man-hours for each worker.
Out such that said target allocation steps is the upper limit, before the respective working
Allocated to each worker, the first small of the man-hour for each worker
Calculating a total, each by dividing the respective first subtotal by the rating (R)
A second subtotal is calculated, and the total man-hours per worker is calculated for each worker.
When calculating each of the first subtotals so that they are substantially equal,
The remaining work not allocated to each worker is
To each of the remaining tasks allocated to the workers.
Work man-hours to each of the second subtotals, and
The mixed production system according to claim 1 , wherein a total man-hour is calculated . 5. A method for integrating a plurality of types of products on a single production line.
By one assemble a set position and performance of the product after completion of assembly
Each work process in a test site that tests and inspects quality
For each worker to process,
Each of the above work steps performed simultaneously in the assembly site and the test site
The work instruction sheet with the work distribution that minimizes the tact
In the operation method of the mixed production system supplied to each worker
Te, the total of the number of steps required for each work to produce a predetermined product
Total work man-hours by the number of processes equivalent to the number of workers
First step to calculate the average man-hour for each worker by dividing
And each of the above works so that the average work man-hour is the upper limit.
Allocated to each worker, the first small of the man-hour for each worker
A second step of calculating a total, and calculating the first subtotal by a rate
The third stage of calculating each second subtotal by dividing by the
And the total man-hours for each worker,
When calculating each of the first subtotals so that they are substantially equal,
The remaining work not allocated to each worker is
To each of the remaining tasks allocated to the workers.
Work man-hours to each of the second subtotals, and
Driving side of the versatile production system comprising: the fourth step of calculating the total work man-hours, the
Law. 6. A plurality of types of products are integrated on a single production line.
Assembling site to assemble one by one and product performance after assembly
Each work process in a test site that tests and inspects quality
For each worker to process,
Each of the above work steps performed simultaneously in the assembly site and the test site
The work instruction sheet with the work distribution that minimizes the tact
In the operation method of the mixed production system supplied to each worker
Te, the total of the number of steps required for each work to produce a predetermined product
The total work time, which is the total
(R) and the rate of each worker
To calculate the target allocation man-hours for each worker
The first step and each of the above operations are performed before the target distribution man-hours becomes the upper limit.
Allocated to each worker, the first small of the man-hour for each worker
A second step of calculating a total, and dividing each of the first subtotals by the rating (R).
A third step of calculating a second subtotal, and the total man-hours per worker is
When calculating each of the first subtotals so that they are substantially equal,
The remaining work not allocated to each worker is
To each of the remaining tasks allocated to the workers.
Work man-hours to each of the second subtotals, and
And the fourth step of calculating the total man-hours.
Characteristic method of operating a mixed production system.