JP6769033B2 - Production volume management system on the production line - Google Patents

Description

The present invention belongs to the technical field of a production volume management system that calculates and displays the additional production volume required by the control target time.

There is a production management method that stores the planned production number within a predetermined production period, calculates and prints the next day's planned production number from the remaining production number obtained by subtracting the cumulative production actual number from the planned production number (Patent Document 1). reference).

JP-A-59-146364

According to the above background technology, only the planned production volume for the next day is calculated and printed, and the manufacturing request of another type of product that suddenly occurs, the change in operating efficiency due to the failure or maintenance of the manufacturing equipment, etc. Due to anomalous events, it is not possible to recognize the additional production volume that needs to be manufactured by the control target time affected by this anomalous event, and the production volume is controlled in response to the anomalous event. Is difficult.
An object of the present invention is to enable accurate control of production volume in response to anomalous events.

In order to solve the above problems, the following technical measures were taken.
That is, the invention according to claim 1 is
A plurality of processing machines (1) for processing a work, a plurality of setup stations (2) for placing a work or a product obtained by processing a work, a plurality of mounting shelves (3) for placing a work, and a work. Alternatively, the transport vehicle (4) travels between the electric transport vehicle (4) for transporting the product, the processing machine (1), the setup station (2), and the above-mentioned storage rack (3). In a production line equipped with route (5),
The processing process of the processing machine (1) and the processing machine (1) to be used differs depending on the specifications of the work, and the pallets are placed in different forms according to the specifications of the work.
The control device of the production line is configured to be able to communicate with the process control server via the relay controller.
In the process control server, the daily allowance target number of products and the machining schedule plan of workpieces with multiple specifications are set and input.
Based on the processing schedule plan, the processed pallet confirmation control for sequentially confirming the presence or absence of the pallet on which the processed work is placed is executed, and a list of pallet combinations that can be sequentially supplied to the setup station (2) is created. Then, a combination of pallets is extracted from the list so that works with specifications with a low progress rate are preferentially set up with respect to the target number of daily allowances, and the pallets are placed on the shelves described above in the transport vehicle (4). It is transferred from (3) to the setup station (2).
The future control target time to manage the production volume of the product and the additional production planned quantity to manufacture the additional product can be set arbitrarily.
Information on the number of finished products manufactured, which is the already manufactured quantity, and the number of processing times of each processing process, which is output from the manufacturing equipment that manufactures the products, and the number of finished products manufactured , which is the target manufacturing quantity of the manufacturing equipment, and each From the information on the number of times of processing in the processing process, the difference between the current production amount and the target production amount is calculated, and the difference is calculated.
When an arbitrary day that is the control target time is input, the additional production amount from the present to the input arbitrary day is calculated based on the difference between the existing production amount and the target production amount at the present time and the additional production planned amount. It is a production volume control system in the production line to be displayed .

According to the invention of claim 1, since the additional production amount required to be manufactured by the control target time is calculated and displayed based on the control target time set arbitrarily, the manufacturing request of the suddenly generated product is displayed. In addition, it becomes easier to determine whether or not it is possible to respond to irregular events such as changes in operating efficiency due to failure of manufacturing equipment or maintenance, and it is possible to accurately manage the production volume in response to irregular events. ..

Plan view showing the FMS production line in an easy-to-understand manner Block diagram showing the communication configuration between the control device of the FMS manufacturing line and the process control server

An embodiment of the present invention will be described below. It should be noted that the following embodiments are merely embodiments and do not limit the scope of claims.

As a manufacturing facility, an FMS manufacturing line for processing a casting to be a workpiece to manufacture a traveling mission case for an agricultural tractor to be manufactured will be described. This FMS production line includes a plurality of (9) processing machines 1 for processing a work, a plurality of (5) setup stations 2 for mounting a work or a product, and a plurality (50 shelves) for mounting a work. A mounting shelf 3 and an electric transport vehicle 4 for transporting a work or a product are provided. A plurality of processing machines 1 are arranged in a row in the left-right direction on each of the left and right sides of a plurality of setup stations 2 arranged in a row in the left-right direction, and a plurality of processing machines 1 are arranged in a row facing the plurality of processing machines 1 and the plurality of setup stations 2. The mounting shelves 3 are arranged in a row in the left-right direction. Further, a traveling path 5 on which the transport vehicle 4 travels is provided between the plurality of processing machines 1, the plurality of setup stations 2, and the plurality of mounting shelves 3, and traveling mission cases having a plurality of specifications can be processed. The configuration is such that a plurality of different types of machining can be performed on the same work. The plurality of processing machines 1 are configured to perform different processing.

Next, an example of processing a traveling mission case having a plurality of specifications will be described. In the FMS production line, for example, in the processing of the traveling mission case of A specification, the processing machine A performs the processing of the first process, the processing machine B performs the processing of the second process, and the processing machine C processes the third process. I do. Further, in the processing of another B-specification workpiece, the processing machine D performs the processing of the first process, and the processing machine B performs the processing of the second process. Further, in the processing of another C-specification workpiece, the processing machine A performs the processing of the first process, the processing machine E performs the processing of the second process, and the processing machine C performs the processing of the third process. In this way, the processing machine and processing procedure used differ depending on the specifications of the work. The work is configured to be mounted on a pallet having a different form for each of these specifications and processing processes.

The control device of the FMS production line sequentially confirms on the mounting shelf 3 whether or not there is a processed pallet on which the processed work from the first process to the final process is placed among the pallets on which the workpieces of each specification are placed. Executes the processed pallet confirmation control. This processed pallet confirmation control is constantly executed, and a list of pallet combinations that can be sequentially supplied to the setup station 2 is created. Then, a combination of pallets is extracted from the list so that the workpieces with specifications with a low degree of completion (progress rate) are set up preferentially with respect to the daily allowance target number of processed workpieces of each specification, and the pallets are selected. First, the processed pallets in the first step are transferred from the loading shelf 3 to the setup station 2 by the transport vehicle 4 in order. When the setup pallet presence / absence sensor detects that there is no pallet in the setup station 2 which is the transfer destination of the processed pallet, the processed pallet is transferred to the setup station 2.

For the processed pallets of each process transferred to the setup station 2, the worker removes the work from the processed pallets of the final process and puts it on the finished product shelf as a finished product, and the process immediately before the final process. The work is removed from the processed pallet and placed on the empty pallet for the final process, and the work is removed from the processed pallet in the process two steps before the final process, and the process one before the empty final process is performed. The work is sequentially removed from the processed pallet on the post-process side and placed on the finished product shelf or the pallet in the next process, such as placing on a pallet. In the setup work, the raw workpiece is placed on the empty pallet of the first process from the shelf for raw products.

At the setup station 2 where the work is placed and mounted on the pallet, when the operator presses the installation complete button, the control device reads the data of the buffer shelf address to be stored from the IC card of the pallet at the setup station. Based on this, the transport vehicle 4 is configured to transfer the data to the mounting shelf 3. Therefore, after the setup work, the operator sequentially presses the installation complete button of each setup station 2 having the pallets, and the control device operates the installation complete button of all the pallets in the setup station 2. It is configured to be transferred to the buffer shelf in order.

The control device of this FMS production line is configured to be able to communicate with the process control server via the relay controller. In the process control server, machining schedule plans for workpieces with multiple specifications, such as the daily daily allowance target number of machined finished products of traveling mission cases of each specification, are set and input, and machining is performed based on this machining schedule plan. In order to perform the work, the processing machine 1 and the transport vehicle 4 of the FMS production line are operated so as to preferentially process the workpiece having a low degree of completion (progress rate), and the workpiece having a low degree of completion (progress rate) is operated. The work is automatically machined while extracting the combination of pallets from the list so as to prioritize the setup.

In addition, the process control server has a configuration in which the processing results of the FMS production line and the processing results of the finished product are aggregated every day, and the results and the processing plan are displayed or printed on paper and output. Therefore, the manager can judge the progress of each specification and each processing process while comparing the actual results with the processing plan on a daily basis. In addition, when an arbitrary day, which is the management target time, is input, the number of finished products manufactured for each specification and the number of machining times for each machining process, which are the additional manufacturing quantities required from the current (current time) to that day, are output. There is. Specifically, the number of finished products manufactured so far, which is the already manufactured quantity, the number of times each processing process is processed, the number of finished products manufactured, which is the target production quantity up to the previous day according to the processing plan, and each processing process. From the number of times of processing, the difference between these production amounts is calculated, and the initial cumulative target production amount, that is, the additional production planned amount from the present to the input arbitrary date is calculated, and the difference between the production amounts and the additional production is calculated. Calculates and outputs the planned amount and the additional production amount required from the present to any day. For example, in the number of finished products manufactured, if the target production volume up to the previous day according to the processing plan is 7, but the progress of the work is delayed and the existing production volume is 5, the difference in production volume will be 2 on the day. If the additional production planned amount up to an arbitrary date entered from is 4 pieces, the additional production amount is 6. That is, while the processing plan is set for each day, the additional production amount up to an arbitrary date is output based on the current production results, which facilitates production control.

Therefore, for example, when a finished product is shipped on a sudden delivery date, it can be easily determined whether or not the required amount can be manufactured by the delivery date, and if it is difficult to manufacture the required amount, another manufacturing facility is used. Can be used together, or manufacturing measures such as suppressing the production of finished products with other specifications can be performed. In addition, when the operation of the processing machine decreases due to failure, maintenance, or deterioration of the processing machine, it is easy to determine whether the desired number of processing is possible by outputting the required number of processing by the delivery date. If it is difficult to perform the desired number of processes, it is possible to take manufacturing measures such as using another processing machine.

It is also possible to communicate from the control device of the FMS manufacturing line to the process control server, output the information from the process control server and have it received by the control device of the FMS manufacturing line, and the workers working on the FMS manufacturing line have a track record. Information such as processing plans and additional production volumes can also be confirmed.

Since the process control server can communicate with the outside via a telephone line, the Internet, or the like, there is a risk of being infected with a computer virus. Therefore, antivirus software is installed on the relay controller to prevent the computer virus from infecting the control device of the FMS production line, and to prevent improper production.

As described above, the manufacturing volume control system configured in the process control server is configured so that the future control target time for managing the manufacturing volume of the product can be arbitrarily set, and is output from the manufacturing facility that manufactures the product. Calculate the difference between the current production volume and the target production volume from the information on the already manufactured volume and the information on the target production volume in which the production volume of the target manufacturing equipment is set in chronological order. At the same time, the additional production planned amount from the present time to the control target time is calculated based on the target production amount at the control target time, and the additional production amount required until the control target time is calculated from the difference between the production amounts and the additional manufacturing planned amount. It is configured to be displayed.

Therefore, based on the control target time set arbitrarily, the additional production amount required to be manufactured by this control target time is calculated and displayed, so that a sudden occurrence of a manufacturing request for a product, a failure of a manufacturing facility, or a failure of a manufacturing facility occurs. It becomes easier to judge whether or not it is possible to respond to anomalous events such as changes in operating efficiency due to maintenance, and it is possible to accurately manage the production amount in response to anomalous events.

Claims (1)

A plurality of processing machines (1) for processing a work, a plurality of setup stations (2) for placing a work or a product obtained by processing a work, a plurality of mounting shelves (3) for placing a work, and a work. Alternatively, the transport vehicle (4) travels between the electric transport vehicle (4) for transporting the product, the processing machine (1), the setup station (2), and the above-mentioned storage rack (3). In a production line equipped with route (5),
The processing process of the processing machine (1) and the processing machine (1) to be used differs depending on the specifications of the work, and the pallets are placed in different forms according to the specifications of the work.
The control device of the production line is configured to be able to communicate with the process control server via the relay controller.
In the process control server, the daily allowance target number of products and the machining schedule plan of workpieces with multiple specifications are set and input.
Based on the processing schedule plan, the processed pallet confirmation control for sequentially confirming the presence or absence of the pallet on which the processed work is placed is executed, and a list of pallet combinations that can be sequentially supplied to the setup station (2) is created. Then, a combination of pallets is extracted from the list so that works with specifications with a low progress rate are preferentially set up with respect to the target number of daily allowances, and the pallets are placed on the shelves described above in the transport vehicle (4). It is transferred from (3) to the setup station (2).
The future control target time to manage the production volume of the product and the additional production planned quantity to manufacture the additional product can be set arbitrarily.
Information on the number of finished products manufactured, which is the already manufactured quantity, and the number of processing times of each processing process, which is output from the manufacturing equipment that manufactures the products, and the number of finished products manufactured , which is the target manufacturing quantity of the manufacturing equipment, and each From the information on the number of times of processing in the processing process, the difference between the current production amount and the target production amount is calculated, and the difference is calculated.
When an arbitrary day that is the control target time is input, the additional production amount from the present to the input arbitrary day is calculated based on the difference between the existing production amount and the target production amount at the present time and the additional production planned amount. The production volume management system in the production line to be displayed .

Images