JPH06348309A - Production control system - Google Patents

Abstract

PURPOSE:To realize the production control system which can accurately grasp the history of lots and is improved in production control precision in a production system which easily cope with abrupt request changes in a production line that is long in lead time and has plural production lines. CONSTITUTION:A terminal machine 6-4 in a process 1 performs operation start processing and outputs a lot discriminating operation card 10 and manufacturing operation 6-2 is performed to manufacture a product 6-4. A terminal machine 6 5 performs completion processing operation 6-3 and lot information is maintained. A terminal machine 6-4 of a process 2 performs operation start processing and outputs a lot discriminating operation card 20. A terminal machine 6-5 of the process 1 performs shipment-reception processing with the cards 20 and 10 and maintains lot history information. Then the product 6-6 is fed to the manufacturing operation of the process 2 to manufacture a product 6-7 and the terminal machine 6-5 maintains the lot information through the completion processing operation 6-3. In processes 3... lot processing similar to that of the process 2 is carried out thereafter.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management system in a production line including a plurality of production processes.

[0002]

2. Description of the Related Art In a production line having a plurality of production steps,
In the conventional production control system, terminals are arranged in each work process, and each terminal is connected to the storage device of the central control unit by a communication line. Then, the work instructions and production result information in each production process are transmitted from each terminal device to the storage device via the communication line, so that the production status such as the number of productions and the degree of progress is grasped.

An example of the above production control system is disclosed in Japanese Patent Laid-Open No. 63-22254.
In the production management system described in this publication, each terminal has a card reading function, and the read card is a personal card to which personal information of each worker is given.
It consists of a serial number card that gives information about the product. Then, one serial number card is attached to each lot that moves between work stations, and the information of the serial number card is read by the terminal of each station, and the history of production completion for each lot is known.

[0004]

However, in the production management system described in the above publication, one for each lot.
There are the following problems because lot management is performed with one serial number card. (A) In a production line with a long lead time (order-to-shipment), it is difficult to deal with a sudden change in the required specifications of the finished product. (B) A production line having a plurality of production steps has a production system having a plurality of rows and a plurality of steps, and the product processing sequence has a plurality of different types of processes even if they are the same. In the system, the lot history may be unknown at the time of outputting the serial number card. That is, for example, as shown in FIG. 13, printing steps P1 to P3
And trimming steps T1 to T4 and substrate shield step S
1 to S4, a module assembly process M1 to M4, and a module assembly process F1 to F4. Then, in this production line, the lot L printed in the printing process P1 is divided into lots L1 and L2 to be supplied to two processes T1 and T2 in the next trimming process T. Trimming process T
At, two serial number cards are output. At the time of outputting these two serial number cards, there is a possibility that the history of the lot may become unknown. Similarly, when the lot L1 is divided into lots L11, L12, L13 supplied to the three steps S1, S2, S3 in the next substrate shield step S, three serial number cards are output. It Even at the time of outputting these three serial number cards, the lot history may become unknown as described above. Furthermore, lot L12
In the next module assembly process M, three processes M2, M
Lots L122, L123, L1 supplied to M3 and M4
If it is divided into 24, the history of the lot may be more unknown.

An object of the present invention is to accurately grasp the lot history in a production system having a long lead time, capable of easily responding to a sudden change in demand, and having a plurality of production lines. It is possible to realize a production control system that is possible and has improved production control accuracy.

[0006]

In order to achieve the above object, the present invention is configured as follows. A production management system for performing production management of a production line having a plurality of production processes, wherein the central management unit and each production process are information-coupled through a communication line, and each production process has A production process work information section is arranged, and each production process work information section displays work instruction information for each production lot in the process to which it belongs on the data carrier based on the work instruction information from the previous process or the central management unit, Lot completion information processing that corrects the production lot history information based on the work initiation information processing unit that outputs and the production completion information in the process to which it belongs and the instruction information from the work initiation information processing unit or the central management unit of the next process And a section.

[0007] Preferably, in the above production management system, the central management unit stores and updates the production information from the production planning unit for drafting a product production plan for the entire production line and each production process work information unit. And a production information storing / updating unit. Further, in the above production management system, preferably, the work start information processing section and the lot completion information processing section have a display section, a work instruction display command section for instructing a work instruction to be displayed on the display section, and a work-in-progress status display. Command unit, progress status display command unit, lot history display command unit,
And a work performance report command unit. Also, preferably,
In the above production management system, each production process has a product inventory in each production process.

[0008]

The work start processing is performed in the work start information processing section, the work information is displayed on the data carrier, and the manufacturing work is started. Next, the lot completion information processing section executes the completion processing work to maintain the lot information. Then, the work start processing of the next step is performed by the work start information processing unit. The work start process information in the next process is transmitted to the lot completion information processing unit in the previous process, and the lot receipt / delivery process is performed. As a result, lot history information is maintained. After that, the product is put into the production work of the next step, and the product is produced. Then, in the same manner as described above, the completion processing work is executed in the lot completion processing section of this process. Lot processing is executed in the same manner in the subsequent steps. Information from the work start information processing unit and the lot completion information processing unit in each process is transmitted to the central management unit, and the central management unit supplies the production command in the production line to each process.

[0009]

Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is an overall schematic configuration diagram of a production management system according to an embodiment of the present invention. This production management system includes a plurality of production processes and has a large number of models, for example, for products such as air flow sensors. Manage production. In FIG. 1, reference numeral 11 is a high-order computer, and the high-order computer 11 includes a production plan planning unit 1 and a production information storage updating unit 2. The production plan planning unit 1 has a function of planning a production plan for the entire production factory. Further, the production information storage updating unit 2 has a function of storing and updating production progress performance data from each production process, lot history data, inventory data, and production technology data set between design or production engineering departments. There is. 3 uses the production planning unit 1 and the production information storage updating unit 2 to
It is a work instruction order determination unit that determines a work instruction order for each production process. The work instruction sequence determination unit 3 is composed of a computer (server) dedicated to data storage. The host computer 11 and the data storage computer 3 constitute a central management unit.

4-1 to 4-n are production process work information sections respectively arranged in the respective production processes, and these production process work information sections 4-1 to 4-n are the work contents of each process and their contents. Information on work order, number of products that can be produced, inventory status of each process, lot history, and production progress is displayed. Further, the production process work information sections 4-1 to 4-n transmit work start information in each production process and completion information at the time of completion of work in lot units to the data storage dedicated computer (server) 3. These production process work information sections 4-1 to 4-n are composed of personal computers. An information transmission network 5 is connected to the production process work information section 4-1 to 4-n for each production process, the host computer 11 and the data storage dedicated computer (server) 3 to transmit and receive information. .

FIG. 2 is a functional block diagram of the production process work information section 4-1. In FIG. 2, the production process work information section 4
-1 includes a work instruction display command unit 41, a work-in-progress status display command unit 42, and a progress status display command unit 43. Further, the work information section 4-1 includes a lot history display command section 44,
A work performance report command unit 45, a display unit 47, and a control unit 46 that controls the operations of the command units 41, 42, 43, 44, 45 and the display unit 47 are provided.

Then, the work instruction display command section 41 executes a work instruction display command of its own process, a producible number and inventory status of the previous process for this work command, and a change command of these commands. Furthermore, the work instruction display command unit 41
Performs output of a data carrier (work card) for identifying a lot at the time of starting work, receipt of a lot based on the information, and transmission of the information to the host computer 11 and the data storage computer 3.

Further, the work-in-progress status display command section 42 receives work-in-process information of the previous process in lot units with respect to the number of producible products from the host computer 11 and the data storage computer 3, and issues a display command of the received information. Run. The progress status display command unit 43 receives the progress information of each process from the host computer 11 and the data storage computer 3, and executes the display command of the received information.

The lot history display command section 44 executes a command to display the lot history on the basis of the lot receipt / payment work information, and sends the information to the host computer 11 and the data storage computer 3. The work result report command unit 45 inputs the production completion information at the time of completing the lot in its own process, and transmits the information to the host computer 11 and the data storage computer 3. And the display unit 4
7 executes display based on the display command from the command units 41, 42, 43, 44, 45. The other production process work information sections 4-2 to 4-n have the same configurations as the production process work information section 4-1 described above, and the work instruction display command section 41 and the work-in-progress state, respectively. Display command unit 42, progress status display command unit 43, lot history display command unit 44
And a work performance report command unit 45, a display unit 47, and a control unit 46. Next, the operation of production management in lot units between production processes will be described. FIG. 3 is a schematic explanatory diagram of the operation of the production management system, and is an example in the case where the lot moves from the production process 1 to the process 3 via the process 2. In FIG. 3, 6-1 indicates the starting work at the time of starting the work based on the work instruction, and 6-2 indicates the manufacturing work of the product. Further, 6-3 indicates a completion processing work for inputting information of the lot into the personal computer 6-5 described later when the lot in the production process is completed. 6-4 is a personal computer which also has a bar code printer for converting the lot number into a bar code based on the lot information and outputting the lot identification work cards 20 and 30, and 6-5 is a lot identification work card. Read the information of
In addition, a personal computer that also has a bar code reader that performs a lot receipt and delivery work for delivering to the next process is shown. This personal computer 6-4 and 6-5
The production process work information section is constituted by.

Then, by the completion processing work of the production process 1, the lot information is input to the personal computer 6-5. Further, the personal computer 6-4 is operated by the start work 6-1 of the production process 2, and the lot identification work card 20 is operated based on the completion, inventory information and work instruction information.
Is output. Personal computer 6 in production process 1
-5 executes lot receipt / payment processing based on the completion processing work and the lot identification card 20. The lot history is maintained by this lot payment / receipt process (correction process)
To be done.

Next, the manufacturing operation 6-2 in the step 2 is performed. Then, when the production work 6-2 is completed, the lot information is input to the personal computer 6-5 of the process 2 by the completion processing work of the production process 2. Furthermore, the personal computer 6-4 is executed by the start work 6-1 of the process 3.
Is operated, and the lot identification work card 30 is output based on the completion, inventory information, and work instruction information. The personal computer 6-5 in step 2 executes the lot receipt / payment processing based on the completion processing work and the lot identification card 30. This lot receipt / payment process maintains the lot history. Thereafter, similar processing is executed up to step 3, step 4, ... Step n.

FIG. 4 is a more specific operation illustration of the operation illustration of FIG. In FIG. 4, step 1 is the first step in this production line. Therefore, since there is no pre-process of this initial process, the work start process is performed in the terminal 6-4 of the process 1 according to the work instruction, and the lot identification work card 10 is output. In this case, the lot size in step 1 is 8000. Next, production work 6-2
Is performed, and the product 6-6 is manufactured. Then, in the terminal 6-5 of the process 1, the completion processing work 6-3, which is the input work of the information of the completed lot, is executed, and the lot information is maintained.

In step 2, based on the completion and inventory number information in step 1 and the work instruction information in step 2 (the lot size in step 2 is 4000), the terminal 6-4 in step 2 performs the work. The start process is performed and the lot identification work card 20 is output. This work card 20 and the previous process 1
On the basis of the work card 10 of FIG. The lot history information is maintained by this payment process. After this work, the product 6-6 (+ work card 20) is put into the manufacturing work process in step 2.

When the production of the product 6-6 in step 2 is completed and the product 6-7 is produced, the completion processing work 6-3 is executed in the terminal 6-5 of step 2. , Maintenance of lot information is executed. In step 3, as in step 2, based on completion in step 2, inventory quantity information and work instruction information in step 3 (the lot size in step 3 is
2000), the work start process is performed at the terminal 6-4 in step 3, and the lot identification work card 30 is output. Based on the work card 30 and the work card 20 of the previous step 2, the terminal 6-5 of the step 2 carries out the payment process. The lot history information is maintained by this payment process. After this work, the product 6-7 (+ work card 30) is put into the manufacturing work process in step 3. Thereafter, in the steps 4, ..., The lot processing similar to the steps 2 and 3 is executed.

In parallel with steps 2 and 3, steps 2a and 2
If there are steps 3a, 3b, ...
These steps 2a, 2b, ..., Steps 3a, 3b, ...
.. have terminals 6-4 and 6-5, respectively. Then, as in steps 2 and 3, maintenance of lot information is executed. That is, for example, step 1
When the lot is divided into two processes, namely, process 2 and process 2a, work start processing is performed in each terminal 6-4 of process 2 and 2a, and work cards 20 and 20a are executed.
Is output. And these work cards 20, 20a
Then, based on the work card 10 of the process 1, the lot receipt and payment process is executed by the terminal 6-5 of the process 1.

5 to 11 show the production process work information section 4-1.
3 is an example of a display screen of the display unit 47 of FIG. FIG. 5 shows a display screen 47-1 based on a command from the work instruction display command section 41.
Is a screen for performing work instructions in each production process, correction of these work instructions, work start, and lot receipt and delivery work. FIG. 6 is an example of a display screen 47-1 based on a command from the work-in-progress status display command unit 42, which is a screen displaying the current work-in-process status for each lot.

7 and 8 show the progress status display command unit 43.
It is an example of a display screen 47-1 based on a command from. 7 is an example in which the progress status of each process is visually displayed based on the work information, and FIG. 8 is an example in which the progress status is numerically displayed. In addition, FIG. 9 and FIG.
It is a display screen 47-1 based on a command from the lot history display command unit 44. 9 is a screen for displaying the lot history based on the lot work information.
Is a screen for inputting the information when the lot is completed. FIG. 11 is a display screen 47-1 based on a command from the work result report command unit 45, and is a screen on which the work results in each process are displayed. Next, in the above production management system, regarding the processing operation of the high-order computer 11 when a sudden demand change occurs with respect to the specifications of the finished product,
The operation will be described with reference to the operation flowchart shown in FIG. In step 100 of FIG. 12, it is determined whether there is a demand variation. If there is no demand variation, the process ends, and if there is a demand variation, the process proceeds to step 101. In this step 101, the final process number n of the production line that satisfies the required variation is substituted into i. This is because first of all, the finished product inventory that meets the required fluctuations is checked. Then, in step 102, i is 0
Or not. If i is not 0, the process proceeds to step 103, and the number of stocks in process No (i) is read from the production information storage update unit 2 (in this case, a predetermined number of stocks in each process or products in production in the process is read). Shall be provided).

Next, in step 104, the process No.
It is determined whether or not (i) has an inventory quantity (intermediate inventory quantity for each process and product quantity being produced in each process) that satisfies the required variation. If there is an inventory quantity that satisfies the request, the process proceeds to step 106, and the temporarily created work instruction change content of each process (process No (i) in this case) is confirmed. And step 1
At 07, whether or not to output the work instruction is displayed on an appropriate display means. Then, when the operator selects not to output the work instruction using the operation means (not shown), the process ends, and when the operator selects to output the work instruction, the process proceeds to step 108. In step 108,
Production information storage updating means 2 which is a storage means for storing a change work instruction
Registered in the memory contents of, and the process ends.

In step 104, when there is no stock quantity that can satisfy the request, the process proceeds to step 105 and the process N
An instruction for responding to the demand variation is temporarily generated and output to o (i), and the process proceeds to step 109. And this step 10
In item 9, even if the specification of the finished product is different from that of the product whose requirement has been changed, the product has the same unfinished product specifications up to the intermediate process. Whether or not the allocation is possible is judged. If the allocation is impossible, the process proceeds to step 111. If the allocation is possible, the process proceeds to step 110. Next, in step 110, the priority order of the work instructions is temporarily changed, and the process proceeds to step 111. Then, in this step 111, the value obtained by subtracting 1 from i is set to i. This is to determine whether or not there is a lot satisfying the required variation by going back to the previous process in order from the final process n. When i is set in step 111, step 102
Return to. After that, the same processing as described above is executed. Then, in step 102, when i becomes 0, that is, when the process to be determined is before the initial process (i = 1), the process proceeds to step 106, and thereafter, step 106,
107 and 108 are executed, and the processing ends.

As described above, according to the embodiment of the present invention, the work start information processing personal computer 6-4 and the lot completion information processing personal computer 6 as the production process work information section are provided for each production process. -5 and the production information from each production process work information section, and determines the production work instruction sequence based on the higher-level computer 11 for planning the production plan and the information from the higher-level computer 11, Data storage computer that supplies production command information to the process work information section (work instruction sequence determination section)
3 and. Then, when a sudden change in demand for the finished product specification occurs, the stock quantity is checked from the final process that satisfies the change in demand. If the number of stocks in the final process is not satisfactory, even if the finished product specifications are different, lots with the same incomplete product specifications in the intermediate production process
Check the inventory quantity by going back through the process. If there is a lot that satisfies the required variation and quantity, the lot is instructed to be assigned to the lot corresponding to the required variation. Therefore, in a production line with a long lead time, even if a sudden change in demand occurs, it can be easily and accurately dealt with. Further, as shown in FIG. 13, a production line including a plurality of production processes may be divided into a plurality of lots from one lot in a production system having a plurality of rows and put into the next process. Even with the work start information processing personal computer 6-4 and the lot completion information processing personal computer 6-5 arranged in each process, the lot history information can be accurately grasped, and the production management accuracy is improved. It is possible to realize a customized production management system.

Further, since it becomes possible to manage the lot unit and collect the progress information in a timely manner, the product and the production information are unified, the early detection of abnormalities is supported, the production is delayed, and the amount of work in process between processes is reduced. It is possible to accurately grasp and improve production efficiency and management accuracy.

Although the production line shown in FIG. 13 is an example of an air flow sensor production line, the present invention is not limited to the air flow sensor production line and can be applied to other product production lines. .

[0028]

Since the present invention is constructed as described above, it has the following effects. In a production management system in which a central management unit and each production process are information-coupled via a communication line, a production process work information unit is arranged in each production process, and each production process work information unit is a previous process or Based on the work instruction information from the central management unit, the work start information processing unit that displays and outputs the work instruction information for each production lot in the process to which the process belongs, the production completion information in the process to which the process belongs, and the next process A lot completion information processing unit that corrects the history information of the production lot based on the instruction information from the work start information processing unit or the central management unit. Therefore, in a production line with a long lead time, it is possible to easily respond to sudden demand changes,
In addition, in a production system having a plurality of production lines, the history of lots can be accurately grasped, and a production control system with improved production control accuracy can be realized.

[Brief description of drawings]

FIG. 1 is a schematic configuration diagram of a production management system that is an embodiment of the present invention.

FIG. 2 is a functional block diagram of a production process work information section 4-1.

FIG. 3 is a schematic explanatory diagram of an operation of the production management system shown in FIG.

FIG. 4 is a more detailed operation explanatory view of the operation of the production management system shown in FIG.

FIG. 5 is a diagram showing an example of a display screen according to an instruction from a work instruction display instruction unit.

FIG. 6 is a diagram showing an example of a display screen according to a command from an in-process state display command unit.

FIG. 7 is a diagram showing an example of a display screen according to a command from a progress status display command unit.

FIG. 8 is a diagram showing another example of a display screen according to a command from a progress status display command unit.

FIG. 9 is a diagram showing an example of a display screen according to a command from a lot history display command unit.

FIG. 10 is a diagram showing another example of a display screen according to a command from a lot history display command unit.

FIG. 11 is a diagram showing an example of a display screen according to a command from a work performance report command unit.

FIG. 12 is an operation flowchart of the host computer when a sudden change in demand occurs.

FIG. 13 is a configuration diagram of an example of a production system in which a production line including a plurality of production processes is configured in parallel.

[Explanation of symbols]

1 Production Planning Department 2 Production Information Memory Update Unit 3 Data Storage Computer (Work Instruction Sequence Determining Unit) 4-1 to 4-n Production Process Work Information Unit 5 Information Transmission Network 6-4 Work Start Information Processing Personal Computer 6 -5 Lot completion information processing personal computer 10, 20, 30 Lot identification work card 41 Work instruction display command section 42 Work in progress display command section 43 Progress status display command section 44 Lot history display command section 45 Work result report command section 46 Control unit 47 Display unit

Claims (4)

[Claims] 1. A production management system for managing production of a production line having a plurality of production processes, wherein each production is performed in a production management system in which a central management unit and each production process are information-coupled via a communication line. A production process work information section is arranged in each process, and each production process work information section is based on work instruction information from the previous process or the central management unit.
Based on the work start information processing unit that displays work instruction information for each production lot in the process to which it belongs on the data carrier, the production completion information in the process to which it belongs, and the instruction information from the work start information processing unit in the next process or the central management unit. And a lot completion information processing unit that corrects the production lot history information, and a production management system. 2. The production management system according to claim 1, wherein the central management unit produces a production plan for producing a product production plan for the entire production line, and production information from each production process work information unit. And a production information storage / updating unit that stores and updates the production management system. 3. The production management system according to claim 1, wherein the work start information processing section and the lot completion information processing section include a display section and a work instruction display command section for instructing a work instruction to be displayed on the display section. In-process status display command section,
A production management system comprising: a progress status display command unit, a lot history display command unit, and a work performance report command unit. 4. The production management system according to claim 1, wherein each production process includes:
A production management system characterized by having a product inventory in each production process.