JP2881799B2 - Production system that automatically collects manufacturing history information - Google Patents

Description

Description: BACKGROUND OF THE INVENTION The present invention relates to a production system for automatically collecting manufacturing history information, and more particularly to a manufacturing system for assembling a plurality of parts into a final product by assembling the manufacturing history information. For production systems that automatically collect.

[Conventional technology]

First, a technical environment related to the present invention will be described.

Usually, when some quality trouble occurs in the final product and it is found that the cause of the trouble is caused by the part, the defective part that caused the trouble is identified, and the production lot of all products in which the defective part was used for manufacturing Is essential for quality assurance. For this purpose, it is necessary to collect and store the correspondence relationship between the production lot of the product and the production lot of the component used in assembling the product, that is, so-called production history information.

By the way, in general, many parts are purchased from a parts maker. After delivery from the parts maker, the parts are once stored in a warehouse, and are discharged from the warehouse to a manufacturing shop when manufacturing is necessary. At the time of warehousing, the receiving lot number is usually assigned to each part, but since this number corresponds to the purchase unit from the part manufacturer, the manufacturing history information includes the manufacturing lot number of the product and the part number. It is sufficient to collect the correspondence with the receiving lot No.

Further, in recent production systems, demand is diversifying, and a shift is being made from low-mix high-volume production to high-mix low-volume production. In a shop of high-mix low-volume production, the number of lots increases, and there are often parts commonly used between different lots. For example, in the case of a printed circuit board manufacturing shop, many parts such as ICs, LSIs, resistors, and capacitors
They are packaged in reels, sticks, etc., and will be delivered to the manufacturing shop in package units. In this case, extra parts are often paid out more than the net required number, so there are surplus parts that were not actually used for production, and these are temporarily stored in the shop as a work in process and used for the next production. Become. As described above, in a manufacturing shop where common parts are stored, it is common that parts are exchanged between lots according to the judgment of an operator / manager.

Further, a normal warehouse management system does not have a function of designating a part receiving lot number when parts are taken out of the warehouse.

For the above reasons, it is difficult to specify the relationship between the receiving lot number and the manufacturing lot number of the parts when the parts are taken out of the warehouse. Therefore, as a method of collecting manufacturing history information, at the time of starting manufacturing in a manufacturing shop, supplying parts to a workstation, and the like, it is necessary to rely on a method of collecting information on used parts each time. .

Also, if there is a manufacturing facility that performs some kind of work (processing) on semi-finished products for each process such as assembly or inspection at a manufacturing shop, this physical unit is called a workstation (hereinafter abbreviated as W / S) Call. Workers outside the manufacturing facilities are also called W / S.

In general, to calculate the component requirements for each W / S,
A manufacturing parts table (hereinafter abbreviated as manufacturing B / M) as shown in the figure is used. The manufacturing B / M is a data table having a tree structure in which child parts, grandchild parts, etc. used for assembling the final product as a parent are linked. Each component has at least a W / S using the component and a required number as data items.

In the example of FIG. 11, it is calculated from the production plan of manufacturing p products A that the W / S b needs p × 3 + p × 2 × 4 parts and the part b requires p × 6 parts. You.

In addition, if the extra parts are issued in excess of the actual required parts, it is necessary to know the surplus number and calculate the required number of net parts by subtracting the previous surplus number from the required number by the above calculation at the next shipment. is there.

Next, a conventional manufacturing history information collecting method will be described.

The conventional manufacturing history information collection method uses a warehouse system that affixes a notifying medium, such as a barcode label, for identifying the receiving lot No.
It consists of a reading device such as a barcode reader that reads a writing medium installed for each W / S, and a manufacturing history information management system that manages the read information on a data table.

Then, every time a part is used in the W / S, a method of collecting the correspondence information between the manufacturing lot and the part receiving lot by inputting the receiving lot number of the part by reading the notation medium with the reading device is performed.

[Problems to be solved by the invention]

The conventional manufacturing history information collection system described above has the following problems.

Due to the variety of component shapes, it is difficult to automatically attach the storage lot No. notation media such as barcodes to the equipment automatically.Also, most manufacturing facilities have a function to automatically read the notation media. do not have. Therefore, the work of attaching the storage lot No. notation medium to each point of parts and the work of reading the notation medium in W / S have to rely on manual work,
There has been a problem that the man-hour for attachment and the man-hour for reading cause an increase in manufacturing cost.

[Means for solving the problem]

The production system for automatically collecting manufacturing history information according to the present invention calculates a net component requirement for each workstation required for manufacturing, issues a delivery request, and creates a lot manufacturing sequence plan for each workstation. And a production management system that issues a lot production instruction for each of the workstations, and issues an outgoing designation in response to the outgoing request and specifies a type, a receiving lot number, and an outgoing order, and Instructs serving by instructing a station, a product type, a receiving lot number, and a quantity, and issues delivery history information including the workstation, product type, receiving lot number, quantity, and delivery order of a destination to which the delivered parts are supplied as information. A warehouse management system to store parts by product type and storage lot number, and instructed according to the delivery instruction from the warehouse management system. Automatic warehouse to supply parts of the type and the receiving lot number in the indicated order and supply them to the serving station, and pick the parts delivered from the automatic warehouse in the order in which they were delivered, and pick up the parts from the warehouse management system. According to the instructions of the serving, the serving station stores the containers in the order described on the transport container according to the work station, the type, and the receiving lot number in the order described on the transport container, and matches the outgoing order with the written order of the transport container; Receiving a lot production instruction from the production management system for each of the workstations, and using the parts discharged from the automatic warehouse at the workstations in accordance with the order indicated on the transport container, thereby allowing the parts to be discharged and used at the workstations. A manufacturing shop consisting of order-matching workstations and said warehouse pipe Receiving the delivery history information from the system, based on the delivery history information, creates a workstation-specific work-in-process BOM including information on a receiving lot number, a quantity, and a use order of components for each workstation, and By comparing the parts list and the lot production sequence plan for each workstation, the correspondence between the production lot and the parts receiving lot is derived,
A production history information management system that writes a derivation result as production history information in a production lot-specific production history information management table including a receiving lot number of a component, a used quantity, and a use order for each production lot.

〔Example〕

 Next, the present invention will be described with reference to the drawings.

FIG. 1 is a block diagram showing one embodiment of the present invention. The production management system 1, the warehouse management system 2, and the manufacturing history information management system 3 are information systems implemented on computers, respectively, and are connected online to exchange information. The warehouse management system 2 controls the automatic warehouse 4, manages incoming and outgoing warehouses, and instructs the serving station 5 to serve.

Normally, parts are purchased from parts manufacturers and accepted and inspected.
After receiving and inspecting the goods, the goods are stored in the automatic warehouse 4. At this time, a storage label is issued and attached for each storage type. FIG. 2 shows an example of the receipt label, and the receipt lot No.
Is represented by a character 8 and a bar code 9. By reading this barcode at the time of storage, the actual storage data is input to the warehouse management system 2 and registered as stock. Parts of the same type are stored separately for each receiving lot No. Parts are stored with the storage label attached.

On the other hand, the production management system 1 calculates the required number of parts by W / S from the production plan and the production B / M. At this time, if there is a part in process at W / S 6a to 6c, this is preferentially allocated to the W / S requirement, and the W / S in-process part is subtracted to the warehouse management system 2 as the net part requirement. Issue a delivery request. FIG. 3 shows an example of a retrieval request. Goods issue request is W / S10 of supply destination
And the required number of data for each W / S.

The warehouse management system 2 receives the above-mentioned exit request and issues an exit instruction to the automatic warehouse 4. Fourth example of leaving instruction
Shown in the figure. The delivery instruction is composed of data of parts 11, storage lot No. 13, and delivery order 14. When there are a plurality of receiving lots No. with the same part name in the automatic warehouse 4, generally, the receiving lot No. 13 of the parts 11 received earlier in time is designated by the principle of first-in first-out. In the case where the number of parts to be delivered spans two or more storage Nos. 13 as in the example of FIG. 4, a plurality of storage lots No. 13 are designated by specifying the delivery order 14. On the other hand, the serving station issues a serving instruction in the format shown in FIG. Serving instructions are W / S10, parts 11, receiving lot No.13, and picking quantity of supply destination
15, and the data in the picking order 16.

The automatic warehouse 4 receives the above-mentioned delivery request, retrieves the parts of the specified type and storage lot No. in the specified order, and supplies them to the serving station 5.

At the serving station 5, the worker visually checks the warehousing label, and the warehousing lot designated by the warehouse management system 2 for serving.
Pick the parts of NO. In order of delivery and collect necessary parts by W / S and send them out to the manufacturing shop. At this time, as shown in FIG. 6, a parts transport container having a partition 17 is used, and when there is a picking instruction of a plurality of receiving lots NO. For parts of the same type, they are stored in different partitions. Further, the components are stored in the partition of the container according to the storage order indicated by the arrow 18 or the like. By the above-described method, parts of the same lot and different receiving lots MO. Are prevented from being mixed in the container, and the picking order can be visually recognized by the arrow of the container.

When the delivery is completed, the warehouse management system 2 reports the delivery history information shown in FIG. The format of the serving instruction and the format of the delivery history information are the same.

In the manufacturing shop, parts delivered by W / S are supplied to the target W / S for use. If there are any in-process parts left over from the last production, use this first,
Next, the parts newly released from the warehouse are used. At this time. If there are parts of the same type that are distributed in a plurality of partitions, the parts 11 are used in the order of arrows 18 shown on the container. According to this rule, the order of the receiving lot No. 13 in the shipping history information shown in FIG.
In / S10, the order of the receiving lot No. 13 using the part 11 becomes equal.

After the production is completed, if there are any surplus parts, keep them separately for each W / S and supply them to the W / S for the next production. In other words, management is performed so that it is not used by transferring to another W / S.

The manufacturing history information management system 3 is a warehouse management system 2
The W / S-based in-process parts list shown in FIG. The W / S in-process parts list is composed of W / S 10, parts 11, receipt lot No. 13, in-process quantity 20 and use order 19 in W / S 10. In the example shown in FIG. 7, there are more than 50 parts a in the W / S after the last production, and since the delivery history information shown in FIG. 5 is received here, 100 parts a-0002 and a- [0003] The figure shows the result of adding 100 pieces.

On the other hand, the production management system 1 receives a W / S-based lot production sequence plan shown in FIG. The lot production sequence plan by W / S is based on the data of W / S10, production lot No. 21, parts 11 used in the relevant W / S, required number of parts 22 for each production lot, and lot production order 23. Be composed. The production history information management system 3 derives a correspondence relationship between a production lot and a part receiving lot from the W / S-based work-in-progress component list and the W / S-based lot production sequence plan.

For example, a description will be given by comparing the cases of FIG. 7 and FIG.
Since the required number of parts a of the part 11 of W / S10 in M-0001 of the production lot No. 21 in FIG. 8 is 30 pieces, the in-process of a-0001 of the receiving lot No. 13 in FIG. 30 pieces are allocated from several 50 pieces, and the number of work in progress is subtracted by the number of pieces to make 20 pieces. Next, since the required number of parts a of the part 11 of the W / S 10 in the production lot No. 21 M-0002 in FIG. 8 is 100 pieces, first, the receiving lot No. a-0001 in FIG. From the remaining 20
Secondly, 80 lots are allocated from the receiving lot No.a-0002.
As a result, the number of works in process of a-0002 is 20 pieces.

According to the above calculation, the production lot M-0001 has the part a-
0001 is used, and the production lot M-0002 has a part a-0001
And a-0002 are used, and the result is written into the correspondence table in the production history information management table for each production lot shown in FIGS. 9 and 10. The production history information management table for each production lot is composed of data of production lot No. 21, parts 11, receiving lot ON.13, used quantity 24, and use order 25.

Since these data tables can be realized on a storage medium on a computer, all data processing can be performed by the computer, and manufacturing history information can be collected and managed without manual operation.

〔The invention's effect〕

As described above, according to the present invention, the receiving lot N
Each time a part is supplied to the W / S, a notation medium such as a barcode label, which is an identifier of O., is attached, and instead of collecting the production history information by reading the notation medium and inputting it into the information system, the At the time of part delivery, the relationship between the W / S that uses the part, the part storage lot number, and the picking order and quantity at the serving station is determined. In the manufacturing shop, the parts that are in process for each W / S should not be transferred to other W / S, and the parts that were delivered from the warehouse should be used in the W / S in the same order as picking at the serving station. With this, the production history information can be automatically calculated and managed by the computer from the delivery history information and the W / S-based lot production sequence plan, so that the man-hours for attaching the notation medium for each part and the production shop W There is an effect that the number of steps for reading the writing medium in / S can be reduced, and as a result, the manufacturing cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a block diagram showing an embodiment of the present invention, FIG. 2 is a plan view showing the format of a warehouse receipt label issued by a warehouse management system, FIG. FIG. 5 is a table configuration diagram showing the format of the delivery instruction, FIG. 5 is a table configuration diagram showing the format of the serving instruction and the delivery history information,
FIG. 6 is a perspective view showing an example of the component transport container, and FIG.
Table configuration diagram showing the format of the in-process bill of materials by S, FIG. 8 is W
Table configuration diagram showing the format of the lot production sequence plan by / S,
9 and 10 are tables showing the format of the production history information management table for each production lot, and FIG. 11 is the production B / M
FIG. 4 is a table configuration diagram showing an example of the table. 1. Production management system, 2. Warehouse management system, 3. Production history information management system, 4. Automatic warehouse, 5. Table serving station, 6a-6c W / S, 7. Inspection inspection station, 8. Warehousing lot No. , 9: warehousing lot number indicated by barcode, 10: W / S, 11: parts, 12: required quantity, 13: warehousing lot number, 14: warehousing order, 15: quantity, 16: picking order, 17 ... Partition, 18 ... Arrow, 19 ... Use order in W / S, 20 ... Work in progress, 21 ... Production lot No., 22 ... Parts required number by production lot, 23 ... Lot production order, 24 ... Quantity, 25 ... Order of use.

Claims (1)

(57) [Claims] The present invention calculates a net component requirement for each workstation required for manufacturing, issues a delivery request, creates and issues a lot manufacturing sequence plan for each workstation, and issues a lot production schedule for each workstation. A production management system that issues a production instruction, receives the outgoing request, issues an outgoing instruction specifying a type, an incoming lot number, and an outgoing order, and sends the workstation, the type, the incoming lot number, and the end of the supply destination workstation; A warehouse management system that issues a delivery history information including information on the workstation, product type, input lot number, quantity, and delivery order of the workstation to which the delivered components are designated and instructs the delivery of the components; And, it is stored according to the receiving lot number, and in accordance with the outgoing instruction from the warehouse management system, the kind and the part of the receiving lot number instructed are instructed. And goods issue in the order,
Automatic warehouse to be supplied to the serving station, picking in the order of leaving the automatic warehouse, according to the serving instructions from the warehouse management system, according to the workstation, and by product type, and by the receiving lot number, to the transport container It was stored in containers in the indicated order, a serving station that matched the order of delivery and the indicated order of the transport containers, and received a lot production instruction for each workstation from the production management system, and was dispatched from the automatic warehouse. By using parts at the workstation in accordance with the order described in the transport container, a manufacturing shop consisting of a workstation that matches the delivery order with the use order at the workstation, and delivery history information from the warehouse management system. Work history based on the delivery history information Create a work-in-process BOM for each workstation containing information on the receiving lot number, quantity, and use order of parts for each application, and compare the work-in-process BOM for each workstation with the lot production sequence plan for each workstation, A manufacturing history that derives the correspondence between lots and parts receiving lots, and writes the derivation results as manufacturing history information in a manufacturing lot-specific manufacturing history information management table that includes the receiving lot number of parts, the quantity used, and the use order for each manufacturing lot A production system for automatically collecting manufacturing history information, comprising: an information management system.