JP4627405B2 - Product production system - Google Patents

Description

  The present invention relates to a product production system, and more particularly to a product production system having a database that stores a production lot number of a part and a product serial number of a product on an assembly line in association with each other.

  Conventionally, for products produced at factories, parts received from parts manufacturers are accepted by the parts acceptance department of the factory, the logistics department in the factory transports them to the production process, and the workers assemble the products at each assembly process. It was. The serial number of the product in which the part is assembled and the manufacturing lot number of the assembled part are recorded in a ledger by the operator, and stored and stored in association with the product serial number.

  As an example of systematizing these operations, Patent Document 1 attaches a barcode label of a product serial number to a product that moves on a production line, and attaches it to a part to be assembled in the process of assembling the part to this product. A technique for recognizing a part lot number by reading a bar code and storing and storing the product serial number of the product and the production lot number of the part in association with each other as electronic information is disclosed.

  On the other hand, in Patent Document 2, a bar code label indicating a part production lot number and a part type is attached to a part box containing a part to be assembled to a product, and the product serial number is also represented by a barcode label on the product to which the part is assembled. A method of pasting, reading a part lot change at a part box replacement timing, and associating a product serial number and a part lot number as electronic information is disclosed.

  However, with the conventional method of associating the product serial number with the part lot number, a barcode reader is arranged for every part assembly process in the manufacturing process, and at the timing when all part lots are switched, the parts box Barcodes must be read, it takes time to read, and the part assembly worker will need to do extra work, increasing the number of man-hours, reducing the man-hours of workers when switching parts lots, There was a problem of being bad.

Also, the parts receiving department at the production plant that accepts various parts sent from the parts manufacturer reads the lot number (barcode) attached to the parts lot of the accepted parts, and the delivered parts receive the parts ordered. Because the type and quantity were checked to see if they were the same, there was a work loss of reading the barcode representing the parts lot twice in the parts receiving department and each part assembly department in the manufacturing process. .
JP 7-36997 A JP 63-170774 A

  The problem of the present invention is that a barcode reader must be arranged in every part assembling process of the manufacturing process, which is a problem in the conventional method of associating the product serial number with the part lot number, It takes a long time to read the barcode of the parts box at the timing of switching the parts lot, and the part assembly worker has to do extra work, which increases the work man-hours when switching parts. This is to eliminate the shortage of man-hours for workers and the inefficiency. It is also an object of the present invention to eliminate the work loss of reading the barcode representing the parts lot twice by the parts receiving department and each parts assembling department in the manufacturing process.

  The object of the present invention is to eliminate the need to read and arrange barcodes in all assembling processes in view of the above-mentioned problems, work efficiency does not deteriorate, and a barcode representing a parts lot is assigned to each part receiving department and each manufacturing process. The object of the present invention is to provide a product production system in which there is no work loss of reading twice by the component assembly department.

  In order to achieve the above object, the product production system according to the present invention is configured as follows.

The first product production system (corresponding to claim 1) manages the delivery of a plurality of parts by means for managing the delivery of the parts put in the parts box, and the assembly parts are put into the assembly line by the assembly line control means. In the product production system that supplies and assembles the product into the product, the means for managing the delivery of the part from the parts manufacturer to the production factory is a means for designating the scheduled delivery time of a plurality of parts based on the production time of the product. , A recording medium that is carried together with the part and recorded in association with at least the designated scheduled delivery time and the production lot number of the part, and the planned delivery time and production lot recorded on the recording medium before delivering the part to the production factory Means for reading the number and sending it to the manufacturing history database; and means for sending the time when the recording medium was read to the manufacturing history database as the part delivery time. The assembly line control means for controlling the assembly process in the assembly line is based on the parts supply instruction means for instructing the supply of the necessary parts for assembling the product in the assembly line and the instructions from the parts supply instruction means. Means for supplying a component box to the line, and a component box remaining number calculating means for calculating the remaining number of parts in the supplied component box. The component box remaining number calculating means includes a component box in the assembly line. as component Ru assembled to the product when it is determined that there remains, to store the components of the production lot number stored in the manufacturing history database, in association with a product serial number of the product in assembly line It is characterized by.

  The second product production system (corresponding to claim 2) is characterized in that, in the above-described configuration, a plurality of types of vehicles are preferably assembled on the assembly line.

According to the product production system described above, the delivery of a plurality of parts is managed by means for managing the delivery of the parts put in the parts box, and the plurality of parts are supplied to the assembly line by the assembly line control means and assembled into the product. In a product production system for manufacturing a product, means for managing the delivery of parts from a parts manufacturer to a production factory includes means for specifying a scheduled delivery time of a plurality of parts based on the production time of the product, A recording medium in which a designated scheduled delivery time and a part production lot number are recorded in association with each other, and a delivery history database that reads the scheduled delivery time and production lot number recorded on the recording medium before delivering the part to the production factory And a means for transmitting the time when the recording medium is read to the manufacturing history database as a part delivery time. The assembly line control means for controlling the assembly process in the assembly includes parts supply instructing means for instructing supply of parts necessary for assembling the product in the assembly line, and parts in the assembly line based on instructions from the parts supply instructing means. Means for supplying a box, and a component box remaining number calculating means for calculating the remaining number of parts in the supplied component box. The component box remaining number calculating means includes a component remaining in the component box on the assembly line. as component when it is determined that Ru assembled to the product and are a component of the production lot number stored in the manufacturing history database, for storing in association with the product serial number of the product of the assembly line, all There is no need to read and place barcodes in the assembly process, work efficiency does not deteriorate, and barcodes representing parts lots are received by the parts receiving department and each part assembly department in the manufacturing process. In effect that the work loss that read twice is eliminated can be obtained.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments (examples) of the invention will be described with reference to the accompanying drawings.

  FIG. 1 shows a configuration of a product production system according to the present invention. In this embodiment, the product is, for example, an automobile. In the production factory 10, a variety of vehicles are produced in a production line 11 that produces vehicles of various types (various specifications).

  The vehicle production system 20 includes an assembly line control (ALC) system 21, a production line 11, a pegging management system 22, parts receiving departments 23-1, 23-2, 23-3, and lots installed in the production factory 10. A change notice device 25, a production planning system 26, a specification management system 27, a parts ordering system 28, a database 40, and a product tag issue system 29 installed in each part manufacturer that can be installed in a management department outside the production plant 10. -1,29-2, 29-3, and component information transmission systems 41-1, 41-2, 41-3. An assembly line control device 24 is formed by the ALC system 21 and the linking management system 22. In the figure, steps 1 to 9 schematically represent each step in the production line 11. For example, process 1 is a piping and wiring unit process, process 2 is an engine room process, process 3 is an interior unit process, process 4 is an exterior unit process, process 5 is a powertrain exhaust gas unit process, and process 6 is Liquid injection step, step 7 is a tire, spare tire step, step 8 is a seat attachment step, step 9 is a door attachment step, and the like. Display terminal devices 30-1, 30-2,... 30-9 are provided in the vicinity of the production line in each process. Each of the above systems is connected by a telecommunication line, and a communication relationship is formed so that signals, data, and information can be transmitted and received through this telecommunication line.

  The ALC system 21 is produced on the display terminal devices 30-1, 30-2,... 30-9 of each process of the production line 11 according to the production plan (production order plan) received from the production plan system 26. Provided with a parts supply instruction section 21a for transmitting and displaying the product specifications, calculating in real time the component parts necessary for each process, and instructing the supply of the parts necessary for assembling the vehicle in the assembly line. The instruction unit 21a transmits the information to the component receiving / dispensing systems 23-A, 23-B, and 23-C provided in the component receiving departments 23-1, 23-2, and 23-3. In addition, a notification signal is sent to the lot change eye notification device 25 when the part lots calculated by the linking management system 22 are switched.

  The production line 11 is a line in which various types of conveyors using a flow operation method are combined, and a large number of various components and sub-assembled component units are assembled to the body flowing through the line. A variety of products (various specifications) are produced in the production line 11 at the production factory 10 in the present embodiment.

  The pegging management system 22 is a component of each component specification paid out to each process from the component acceptance / delivery system 23-A, 23-B, 23-C of the component acceptance department 23-1, 23-2, 23-3. The parts lot information of the box is received, and the parts lots on the line side of each process of the assembly line 11 are always identified. Further, the linking management system 22 receives the specifications of the products currently in each process transmitted from the ALC system 21, and uses the information to specify the part numbers to be assembled to the products currently in each process. The part number to be assembled is acquired by comparing with the above, and it is determined that the part is assembled to the product from the parts box of the part in the process by the worker. The lot information of the part and the product serial number are linked and stored in the database 40. The association management system 22 includes a component box remaining number calculation unit 22a that calculates the remaining number of component boxes.

  The parts receiving departments 23-1, 23-2, and 23-3 are in the assembly plant 10 and input the time when the parts box was delivered using the parts receiving and dispensing systems 23-A, 23-B, and 23-C. Then, the parts box is temporarily stored in the storage space of the assembly factory. As this storage space, an automatic warehouse disclosed in Japanese Patent No. 2559159 may be used.

  FIG. 2 is a block diagram of the parts receiving / dispensing system. The parts receiving / dispensing system 23 -A (B, C) includes a control device 50, an input device 51, an output device 52, a conveyance component storage area 53, and a database 40. The control device 50 controls the input device 51, the output device 52, the conveyance component storage area 53, and the database 40. The input device 51 is a device for inputting the time when the recording medium is read from the component delivery time input device 54 as the component delivery time, and inputting the component information from the ALC system 21. The output device 52 is a device that outputs information on a storage location where the parts box is stored or information on a storage location where the parts box is stored to the system of the automatic warehouse 103. The database 40 includes a vacant storage location where the parts box can be stored, a storage location storage area 55 for storing a storage location where the parts box is already stored, a scheduled delivery time of the parts box, and the actual product of the parts box. A part delivery scheduled time / part lot number storage area 56 for storing the part lot number and part name recorded in the vote is provided. In addition, a transport part storage area 53 for storing a parts box transported from the automatic warehouse 103 is provided.

  In the case of the automatic warehouse 103, after the parts delivery time is input by the parts delivery time input device 54 at the entrance of the automatic warehouse 103, it is automatically carried into a predetermined section by a crane or a conveyor (not shown). The parts delivery time input from the parts delivery time input device 54 is input from the input device 51 of the parts receiving / dispensing system 23A (B, C), and the control device 50 stores an empty storage location from the storage location storage area 55 of the database 40. Is stored in the storage location storage area 55 together with the parts delivery time, and the storage location information is output from the output device 52 to the control device (not shown). ) And the parts box is carried to the storage location by a crane or a conveyor by the control device. Further, the parts receiving / dispensing systems 23 -A, 23 -B, and 23 -C detect the storage location where the corresponding type of parts box is stored based on the information received from the ALC system 21. In that case, when the parts are the same, it is desirable to pay out the parts boxes to the assembly process in the order of reading the delivery times of the respective parts boxes. If a predetermined parts box is taken out from a predetermined storage location, the parts lot information of each part can be specified by collating with the parts delivery scheduled time from the parts delivery time inputted from the delivery time input device at the time of acceptance. In the case of the automatic warehouse 103, when a necessary part is instructed from the part supply instructing unit 21a of the ALC 21, the control device 50 retrieves the part name from the storage area 56 from the database 40, and stores the storage location by the part name. The corresponding storage location is searched from the area 55, and the information of the searched storage location is transmitted to the control device of the automatic warehouse 103. The control device automatically controls the corresponding parts box by controlling the crane and the conveyor. It is conveyed to the parts exit. Then, the parts box is supplied to the assembly line by the worker.

  In FIG. 1, a lot change notice device 25 is a lot change notification lamp device that notifies by blinking of a lamp at the time of lot change, and preferably includes a lot change notification automatic announcement device that is notified by voice at the time of lot change. On the linking management system 22, the theoretical part lot switching timing is when the number of remaining parts in the part box on the line side becomes zero. By installing a lamp or automatic announcement device on the line side to notify the assembly operator of lot switching of this theoretical part, lot switching is notified to the operator. The line operator can easily recognize the case where the part change of the part box of the part to be used is actually changed from the theoretical change of the lot.

  The production planning system 26 creates a production plan for products to be produced in the line 11 for producing a variety of products, and also creates a production ranking plan that determines the order of actual production in the factory according to the production plan. System.

  The specification management system 27 registers and manages part specifications used for various types of products. Specifically, a parts list for each vehicle type is registered, and if a vehicle type is specified, a part necessary for assembling the vehicle type can be searched.

  The parts ordering system 28 calculates the required amount of parts according to the produced production plan, determines the delivery date / time and quantity for each part manufacturer, and places an order. This parts ordering system 28 constitutes a part of means for managing delivery of parts, and is also means for designating scheduled delivery times of a plurality of parts based on production times of products.

  The in-stock slip issuing systems 29-1, 29-2, and 29-3 are installed in a parts manufacturer, and are used to identify the ordering information on the ordering side for the parts to be delivered when delivering to a product factory at a specified date and time. , Issue the attached product slip. At this time, based on the part order received from the part ordering system 28, a standard product slip of a unified standard is created. The actual product slip also includes a lot number, which is an arbitrary number for identifying a production lot of parts.

  In addition, a parts manufacturer attaches a product slip in which a part production lot number is recorded to a part to be shipped, and specifies a part delivery time to deliver each part box to a part box in which the part is put. A storage medium such as a tag is also attached to the parts box and is recorded together with at least the designated scheduled delivery time and the part production lot number.

  The component information transmission system 60 is provided in the component manufacturer, and is means for reading the component delivery scheduled time and the manufacturing lot number recorded on the recording medium and transmitting them to the database (manufacturing history database) 40. The block configuration of FIG. The configuration is shown in the figure. A control device 61, an input device 62, a storage device 63, and a component information transmission device 64 are provided. The control device 61 controls the input device 62, the storage device 63, and the component information transmission device 64. The input device 62 and the storage device 63 constitute a component information input storage device 65, and the input lot 69 and the scheduled delivery time of the component recorded on the actual product slip 67 of the component put in the component box 66 are input by the input device 69. The part name, the input production lot number, and the part delivery scheduled time are stored as part information associated with each other. The part information transmission device 64 transmits the manufacturing lot number, the scheduled part delivery time, and the part name stored in the part information input storage device 65 to the database 40 of the vehicle manufacturing factory for storage. This parts information transmission system 60 is a part of means for managing delivery of parts.

  FIG. 4 is a flowchart for explaining the outline of the creation of the linkage data (data relating the product serial number and the assembled part lot number) in the actual process in the linkage management system 22. First, the linking management system 22 can identify the specifications of the product in the process from the ALC system 21. For example, it is recognized as a sedan for North America (step S10). Next, the specification management system 27 is used to search for the types of parts to be assembled in this process to the North American sedan (step S11). It is determined by searching the data of the parts receiving / dispensing systems 23-A, 23-B, and 23-C whether or not the type of the searched parts is being transported in the process (step S12). As a result, when the type of the retrieved part is not conveyed on the process, error processing is performed (step S17), and the process ends. When it is determined that the type of the retrieved part is being transported on the process, the pegging management system 22 is still in the parts box from the timing when the lot of the part has changed and the serial number of the product used. It is determined whether there are any remaining parts (step S13). If it is determined that no parts remain in the parts box, error processing is performed (step S17), and the process ends. If it is determined that there are still parts in the parts box, it is determined that the parts are assembled from the parts box to the product in the process, and the lot number is read (step S14). The product serial number of the product and the manufacturing lot number of the part are stored in the database 40 of the linking management system 22 (step S15). It is determined whether the work is finished (step S16). If the work is not finished, step S10 is executed. If the work is finished, it is finished.

  Thus, since the product serial number of the vehicle and the production lot number of the parts mounted on the vehicle are stored in the database 40, if the product serial number of the vehicle is known, the production lot of the parts mounted on the vehicle is obtained. If the number is known and the production lot number of the part is known, the product serial number of the vehicle on which the part is mounted can be identified.

  Next, an example of the overall processing of the vehicle production system will be described with reference to the flowcharts of FIGS. 5 to 8, the process outline diagram of FIG. 9, and the tables shown in FIGS.

  First, a production plan for a product to be produced is created in a line for producing a variety of products by the production planning system 26 (step S20). This production plan usually includes, for example, the order status from customers and expected production products other than orders, and is initially shown in FIG. 10 for each MTC (model (M), type (T), color (C)). The number is set as shown in Table 1. In Table 1, column C10 represents MTC, column C11 represents vehicle type, column C12 represents normal or 4WD drive, column C13 represents domestic or export destination, and column C14 represents the number of vehicles. In the production planning system 26, by using the production order plan creation method included in this system, the order of products produced on the day (production order plan) is determined. Then, the production plan (production order plan) is transmitted to the parts ordering system 28 (step S21).

  Next, the part ordering system 28 that has received the production plan from the production planning system 26 retrieves the part specification from the specification management system 27 that registers and manages the part specifications used for various types of products, and creates the produced production plan. Accordingly, the required amount of necessary parts is calculated (step S22). This is done as follows. The parts used depend on the specifications of the products according to the MTC in the production plan that has been sent. These are managed by the specification management system 27, and Table 2 shown in FIG. 11 is obtained using this information. In Table 2, column C20 represents MTC, column C21 represents vehicle type, column C22 represents normal or 4WD drive, column C23 represents domestic or export destination, and column C24 uses part A. Column C25 indicates whether or not the component B is used, column C26 indicates the type of component C, and column C27 indicates the type of component D. As can be seen from Table 2, the parts A and B are used for all products produced on the day, but the parts C and D are different depending on the MTC. That is, C01 is used for vehicles with MTC of N, P, S, T, W, and X, and C02 is used for vehicles with MTC of Q, R, U, V, Y, and Z. The component D uses D11 for MTC N and Q, D12 for MTC P and R, D21 for MTC S and U, D22 for MTC T and V, and MTC W and Y Uses D31, and MTC uses X32 and D32. By combining Table 1 shown in FIG. 10 and Table 2 shown in FIG. 11, the number of parts necessary for production of the product on the day is calculated. This is shown in Table 3 shown in FIG. In Table 3, column C30 represents the part name, column C31 represents the MTC to be applied, and column C32 represents the required number of corresponding components. Based on the required amount (required number) of the parts shown in Table 3, the parts ordering system 28 determines the delivery date / time and quantity for each part manufacturer and places an order (step S23).

  The part manufacturer that has received the part order manufactures the part (step S24), and codes the part number / quantity / part lot information (manufacturing lot number) by the invoice issue system 29-1, 29-2, 29-3. An actual product slip with a machine-readable medium attached is created (step S25). At this time, the actual product slip issuing systems 29-1, 29-2, and 29-3 create actual product slips of a unified standard based on the part order received from the part ordering system 28. Next, the part information transmission system 60 inputs the production lot number recorded on the actual product slip of the part put in the part box and the scheduled part delivery time recorded on the tag attached to the part box, and the inputted manufacturing. The lot number and the scheduled part delivery time are stored as associated part information, and the stored production lot number and the scheduled part delivery time are transmitted to the database 40 of the vehicle manufacturing factory for storage (step S26).

  FIG. 6 shows a processing flowchart in the component information transmission system 60. First, the part delivery scheduled time of the tag of the parts box is read (step S261). Next, the actual product slip is read (step S262). The control device associates the scheduled part delivery time with the lot number of the actual product slip and stores them in the storage device (step S263). It is determined whether all the parts boxes to be shipped have been stored (step S264). If not completed, the process returns to step S261. If completed, the component information including the component name, the scheduled delivery time, and the lot number is transmitted to the database 40 by the component information transmitting device 64 (step S265). ). After that, the product tag and the tag are attached to the parts box containing the parts and are sent to the assembly factory (step S27 (FIG. 9A)).

  Next, as shown in FIG. 7, in the parts receiving department, when the parts are delivered (FIG. 9B), the parts receiving and dispensing systems 23-A, 23-B, 23-C are used to The delivery time is automatically read by the reading device 54 (step S28, FIG. 9C), and the parts box is temporarily stored in the storage space of the assembly factory. At the same time, it is stored in the database 40 (FIG. 6 (d)). At this time, in the case of the automatic warehouse 103, the parts box is automatically conveyed to a predetermined section by a crane or a conveyor. At the same time as reading the actual product slip, the location where the parts box is temporarily stored is input to the parts receiving / dispensing system 23-A, 23-B, 23-C, and the parts receiving / dispensing system 23-A, 23-B. , 23-C is stored in the database 40 (step S29).

  Next, the processing of this system when an automobile is produced on the production line (FIG. 9E) will be described with reference to the flowchart of FIG. First, the production planning system 26 transmits a production plan (production order plan) to the ALC system 21 (step S40). Receiving the production plan, the ALC system 21 creates a production setup instruction for each process (step ST41). The prepared setup instructions in each process are transmitted to the line terminals 30-1, 30-2,... 30-9 on the line side of the production line 11 and transmitted to the linking management system (step S42). ). The line terminals 30-1, 30-2,... 30-9 display the received setup instruction on the display device (step S43). The worker performs assembly work in each process according to the setup. Next, the component shake necessary for each process is calculated in real time and transmitted to the component receiving and dispensing systems 23-A, 23-B, and 23-C (step S44). In the parts receiving / dispensing systems 23-A, 23-B, and 23-C that have received the parts arrangement instruction, the parts are paid out to each process (step S45). At that time, the parts receiving / dispensing system 23-A, 23-B, 23-C detects the location where the delivery time of the corresponding type of parts box is stored based on the part information received from the ALC system 21, and Display location. The worker takes out the corresponding parts box from the displayed storage location and transports it to the line side. In the case of an automatic warehouse, the parts box is automatically conveyed to the exit port by a conveyor or a crane. The parts information such as the production lot number of the corresponding part identified and collated with the delivery time of the parts box and the scheduled delivery time is transmitted to the linking management system (step S46).

  The linking management system 22 receives the part lot information of the parts box of each part specification delivered to each process from the parts acceptance / delivery system 23-A, 23-B, 23-C, and each process of the assembly line 11 The lot of parts on the line side is always identified. Further, the linking management system 22 receives the specification of the product currently in each process transmitted from the ALC system 21 (step S42), and uses the information to specify the part number to be assembled to the product currently in each process. The part number to be assembled is acquired by collating with the specification management system (step S47), and it is determined that the part is assembled to the product by the worker from the part box of the part in the process. The lot information of the part and the product serial number are linked and stored in the database (step S48). It is determined whether or not the number of parts in the parts box has reached a predetermined number (step S49). If the number of parts reaches the predetermined number, the ALC system 21 is notified that the number of parts has reached the predetermined number (step S50). The ALC system 21 instructs the parts again (step S44). If the number of parts in the parts box becomes zero and lot switching is performed, information on the lot switching is transmitted to the lot change notice device 25 (step S51).

  The lot change notice device 25 that has received the lot change information notifies the operator of the lot change by lighting the lamp and making an announcement (step S52). As a result, the line operator can easily recognize the change in the lot change in which the part box of the part to be used is actually changed from the theoretical change in the lot.

  As mentioned above, in this system, the time of delivery is specified when parts are ordered, and the parts manufacturer specifies the lot of parts to be delivered at the specified time and sends them to the vehicle manufacturing factory. Since it is possible to grasp the lot of the parts carried in at a given time as an outline, it is possible to grasp from what time to what time the lot switching timing was. From this, it is possible to know which serial number car was worked in each process in each process as the time, so that the lot and the car body number can be linked.

  Steps S27 to S50 will be described more specifically with reference to the tables shown in FIGS. Parts delivered from a parts maker are housed in a parts box. However, since the parts box is different for each part, the number of parts accommodated per part box is different. This is shown in Table 4 shown in FIG. In Table 4, a column C40 represents a component name, and a column C41 represents a component box accommodation number. For example, component A has a component box accommodation number of 50, and component B has a component box accommodation number of 60. Further, the production ranking plan created by the production planning system is shown in Table 5 shown in FIG. In Table 5, column C50 represents a serial number, column C51 represents a vehicle type, column C52 represents 4WD or normal driving, column C53 represents a domestic or export destination, column C54 represents MTC, and column C55. Represents the line insertion time. The production process is shown in Table 6 shown in FIG. In Table 6, a column C60 represents a process, a column C61 represents a part to be traced, and a column C62 represents an arrival time after input. For the sake of simplicity, assuming that the product production line flows in 1 minute tact (the time given to the work of one process), if the time to the work place is added to the time put in the line, the relevant The time spent working on the product can be calculated.

  That is, as shown in Table 6 of FIG. 15, the product to be worked arrives at the process 10 which is the process of assembling the part C 10 minutes after the line is put in. As shown in Table 5 of FIG. 14, the product serial No. 15 is input at 8:44, so that the process 10 arrives at 9:54.

  In each process, since there is no part to be assembled in the product, the work cannot be performed. Therefore, the MTC product to be assembled is planned to be transported from the parts receiving department to each process before reaching each process. For example, the part A used on the day assembled in the process 3 is 8:30 on the line input time when the serial number 1 that is the first product on the day arrives, and 8:33 on the third part. I need it. Although it may arrive at the last minute, it is planned to arrive at 8:28 with a certain margin (for example, 5 minutes).

  On the other hand, if all parts used on the day are transported at the same time, the space in the line workshop will be narrowed, and mistakes may occur if there are similar parts. At a certain time, a parts transportation plan is prepared in which the required amount is stored in the parts box and delivered. For example, as shown in Table 4 of FIG. 13, in the case of the part A, since the number of parts stored in one part box is 50, only 50 parts are stored on the line side at the time described above (8:28). Parts are transported. Since this part A is used for all products manufactured on the same day, one piece is consumed per minute and the 50th unit from the start of manufacture, and the part box for part A will be empty after 50 minutes.

  The ALC 21 calculates from the relationship between the production order plan and the product specifications, and creates the next parts transportation plan. Based on this plan, the part A from the parts receiving department transports the second part box to the process 3 at 9:18.

  As in the case of the part A, it is easy when there is a single part to be assembled in the product in one process, but in a process having a plurality of types of parts assembled in the process, the result is as shown in Table 7 shown in FIG. (A) of Table 7 represents the part number C401 (4WD) for lot number C401, column C70 represents the number of components, and column C71 represents the serial number of the assembled vehicle. (B) in Table 7 represents the part number (20WD) for the lot number C20, the column C72 represents the number of components, and the column C73 represents the serial number of the assembled vehicle. Further, (c) in Table 7 represents the part number C402 (4WD) for the lot number C402, the column C74 represents the number of components, and the column C75 represents the serial number of the assembled vehicle. (D) of Table 7 represents the part number C2 for the lot number C20, column C76 represents the number of components, and column C77 represents the serial number of the assembled vehicle. (E) in Table 7 represents the part number C03 (4WD) for lot number CC03, column C78 represents the number of components, and column C79 represents the serial number of the assembled vehicle. (F) in Table 7 represents the part number C20 (2WD) for the lot number C20, the column C80 represents the number of components, and the column 81 represents the serial number of the assembled vehicle. For example, as shown in Table 6 of FIG. Also, as shown in Table 4 of FIG. 13, there are two types of parts C, 4WD and normal 2WD. Further, the number of parts C accommodated in the parts box is different for 4WD and 2WD. That is, as shown in Table 4, the number is 25 for C02 (for 4WD) of component C and 20 for C01 (for 2WD).

  Referring to the production order plan table, the parts are used as shown in Table 7 shown in FIG. That is, the product for the day arrives at the assembly process 10 for the part C at 8: 30 + 9: 8: 39. The first assembled part C (for 4WD) is transported at 8:34, 5 minutes before 8:39. The parts box contains 25 parts C (for 4WD). Referring to the production order of products, since the same MTC products up to serial number 25, the same part C (for 4WD) is used (Table 7 (a)), but the MTC changes from serial number 26. As shown by an arrow Y10 in FIG. 13, the used part changes, and the part C (for 2WD) is used (Table 7 (b)). Part C (for 2WD) contains 20 parts boxes. It will be transported at 8:59, 5 minutes before 9:04, when parts C (for 2WD) will be used.

  In this state, in the process 10 for assembling the part C, the 4WD for the part C and the 2WD for the part C are placed at the same time. That is, in this example, from 8:59 to 9: 3, two types of parts boxes are placed under the operator of the process 10. Furthermore, according to the production order plan, the part C (for 2WD) will be empty after 20 minutes, so the next part box must be transported to the process 10 5 minutes before 9:24. . When the parts box is changed with the same parts as indicated by the arrow Y11, the parts production lots of the manufacturers that produce the parts may be different.

  According to the production order plan, there is an MTC product that assembles part C (for 4WD) in process 10 at the stage when five pieces from the second part box of part C (for 2WD) shown in Table 7 (d) are used. come. Since the parts box of part C (for 4WD) shown in Table 7 (a) has been emptied by assembling to the product at 9: 3, serial number 51 is placed on the line at 9:20. It is put in, and as shown by the arrow Y12, use begins at 9:30, 10 minutes after that. Therefore, the second part box of the part C (for 4WD) shown in Table 7 (c) is transported at 9:25. At this stage, a parts box in which 15 parts C (for 2WD) shown in Table 7 (d) remain and a second parts box of parts C (for 4WD) shown in Table 7 (c) are placed. Will be. After using part C shown in Table 7 (c), use part C (for 4WD) shown in Table 7 (e), use up to 9 parts, and then use part C (for 2WD) shown in Table 7 (d) ) As shown by an arrow Y13. When 20 parts C (for 2WD) shown in Table 7 (d) have been used, the parts are assembled from the parts box of the next part C (for 2WD) shown in Table 7 (f) as indicated by arrow Y14.

  FIG. 14 is a diagram showing the flow of vehicles on the production line 11 when this system is used. Vehicles with product serial numbers 001 to 025 are vehicle type A, vehicles with product serial numbers 026 to 047 are vehicle types B, vehicles with product serial numbers 048 to 050 are vehicles with vehicle type C, and product serial numbers 051 to 076. Vehicle type D, vehicle serial number 077 to 085, vehicle type E, and vehicle serial number 086 to 121, vehicle type F flows. At this time, the vehicle type A, the vehicle type D, and the vehicle type E are the parts A (for 4WD), the parts B, and the parts C, and the vehicle types B, C, and F are the parts A (for 2WD), the parts B, and the parts C. It is done. In the vehicle of product serial number 001, parts A (4WD), B, and C that are lot-switched are used and flowed to the production line 11. When it becomes the vehicle of the product serial number 026, since it is changed to the vehicle type B, the part A (4WD) is changed to the part (2WD) and becomes a new lot. Further, in the vehicle with the product serial number 047, the lot switching of the part A (2WD) is performed, and when the vehicle has the product serial number 051, both the parts A (4WD) and B are switched over. The part C is lot-switched in the vehicle having the product serial number 061, and the part A (2WD) is lot-switched in the vehicle having the product serial number 076. Parts A (2WD) and B in the vehicle of product serial number 101 are lot-switched. In addition, the part C is lot-switched in the vehicle having the product serial number 121. In this manner, lot switching is performed on the parts assembled in the vehicle. When these lots are switched, the lamp switching timing calculated by the system is lit and announced by the notification device, and it can be confirmed whether the lot switching is correct. If parts are forgotten to be attached, the display of the lot notification device and the timing of lot switching are not correct, and it can be confirmed without missing that the parts are forgotten.

  Each time the parts box is transported to the line, the product serial number of the vehicle and the manufacturing lot number of the parts are recorded together by the database of the linking management system. For example, in this example, parts A (4WD), B, and C of the production lot number 1 are mounted from the vehicle of the product serial number 001, and the parts A (4WD) of the production lot number 1 are mounted up to the vehicle of the product serial number 025. Is recorded. The part A (4WD) of the production lot number 2 is mounted on a vehicle having a product serial number 051 to 075, and the next production lot number 3 is mounted on a vehicle having a product serial number 076 to 085. The part B with the production lot number 2 is mounted on vehicles having product serial numbers 051 to 100. The part C with the production lot number 2 is mounted on vehicles having product serial numbers 061 to 120. The part A (2WD) of the production lot number 1 is mounted on vehicles having product serial numbers 026 to 046. The part A (2WD) of the production lot number 2 is mounted on the vehicles having the product serial numbers 047 to 100. The part A (2WD) of the production lot number 3 is mounted on the vehicle having the product serial number 101 to 121, and the part C of the production lot number 3 is mounted on the vehicle of the product serial number 121. The database records that vehicles with product serial numbers 001 to 025 are mounted with part A (4WD) of production lot number 1, part B of production lot number 1, and part C of production lot number 1. Is done. It is recorded that vehicles with product serial numbers 026 to 046 are mounted with a part A (2WD) with a production lot number 1, a part B with a production lot number 1, and a part C with a production lot number 1. It is recorded that vehicles with product serial numbers 047 to 050 are mounted with part A (2WD) of production lot number 2, part B of production lot number 1, and part C of production lot number 1. It is recorded that vehicles having product serial numbers 051 to 060 are mounted with a part A (4WD) with a production lot number 2, a part B with a production lot number 2, and a part C with a production lot number 1. It is recorded that vehicles with product serial numbers 061 to 075 are mounted with part A with production lot number 3, part B with production lot number 2, and part C with production lot number 2. It is recorded that the vehicles from product serial number 076 to vehicle 85 are mounted with part A (4WD) of manufacturing lot number 3, part B of manufacturing lot number 2, and part C of manufacturing lot number 2. It is recorded that vehicles with product serial numbers 086 to 100 are mounted with part A (2WD) of production lot number 2, part B of production lot number 2, and part C of production lot number 2. It is recorded that vehicles having product serial numbers 101 to 120 are mounted with a part A (2WD) with a production lot number 3, a part B with a production lot number 3, and a part C with a production lot number 2. The product serial number 121 records that the part A with the manufacturing lot number 3, the part 3 with the manufacturing lot number 3, and the part C with the manufacturing lot number 3 are mounted.

  In this way, the product serial number of the vehicle and the manufacturing lot number of the parts mounted on the vehicle are recorded in the database. Therefore, if the product serial number of the vehicle is known, the manufacturing lot number of the parts mounted on the vehicle If the manufacturing lot number of a part is known, the product serial number of the vehicle on which the part is mounted can be identified. In addition, since the change of the theoretical part lot on the database side can be notified to the operator by the lot change notification means, is the timing of changing the parts box synchronized with the theoretical lot change on the database side? You can be notified.

  The present invention is used in a production process in which a production lot number of a part incorporated in a product and a product serial number of the product are associated with each other and recorded in a database.

It is a figure which shows the structure of the whole system with which the vehicle production system which concerns on this invention is applied. It is a block block diagram of a components acceptance / dispensing system. It is a block block diagram of a components information transmission system. It is a flowchart explaining preparation of linked data. It is a whole process flowchart of the vehicle production system which concerns on this invention. It is a flowchart which shows the procedure until components information transmission in a components maker. It is a whole process flowchart of the vehicle production system which concerns on this invention. It is a whole process flowchart of the vehicle production system which concerns on this invention. It is a schematic diagram which shows the flow of the operation | work using a vehicle production system. It is a table | surface which shows the number of production according to MTC. It is a table | surface which shows the required components according to MTC. It is a table | surface which shows required number of parts. It is a table | surface which shows the number of parts box accommodation for every part. It is a table | surface which shows a production order plan. It is a table | surface which shows a production process. It is a table | surface which shows the production process in the process with multiple types of components. It is a figure which shows the flow of the vehicle in a production line, and parts lot switching.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Production factory 11 Production line 20 Vehicle production system 21 ALC system 21a Parts supply instruction part 22 Pegging management system 22a Parts box remaining number calculating part 23-1 Parts receiving department 23-2 Parts receiving department 23-3 Parts receiving department 24 Assembly Line control device 25 Lot change notification device 26 Production planning system 27 Specification management system 28 Parts ordering system 29-1 Actual product issue system 29-2 Current product issue system 29-3 Actual product issue system 40 Database 54 Reading device 60 Parts information Transmission system 64 Parts information transmission device 65 Parts information reading storage device 103 Automatic warehouse

Claims (2)

In a product production system that manages the delivery of a plurality of parts by means for managing the delivery of parts placed in a parts box, supplies the plurality of parts to the assembly line by assembly line control means, and manufactures the product by assembling it into the product.
The means to manage the delivery of parts from the parts manufacturer to the production plant is
Means for designating scheduled delivery times of the plurality of parts based on the production time of the product;
A recording medium that is carried together with the part and recorded in association with at least the designated scheduled delivery time and the production lot number of the part;
Means for reading the scheduled delivery time and the production lot number recorded in the recording medium and sending them to the production history database before delivering the parts to the production factory ;
Means for transmitting the time when the recording medium is read to the manufacturing history database as a part delivery time,
The assembly line control means for controlling the assembly process in the assembly line is:
Parts supply instruction means for instructing supply of necessary parts for assembling the product in the assembly line;
Means for supplying the parts box to the assembly line based on an instruction from the parts supply instruction means;
A component box remaining number calculating means for calculating the remaining number of parts in the supplied component box,
The parts box computing means as said when it is determined that the remaining parts in the parts box assembly line parts Ru assembled to the product, the lot number of the stored in the manufacturing history database component And a product serial number of the product in the assembly line, and stored.   The product production system according to claim 1, wherein a plurality of types of vehicles are assembled in the assembly line.

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