DE102008052086A1 - Method for requesting or preparing material in production environment, involves preparing material in predetermined quantity in loading unit corresponding to number of products to be manufactured - Google Patents

Abstract

The method involves preparing a material (A) in a predetermined quantity in a loading unit (LT1,LT2) corresponding to a number of products (P1 to P6) to be manufactured. A signal is released as request of a material delivery (ML) after removing the material from the loading unit. A material holding (MB) is reduced by the material prepared in the loading unit, and a product manufactured last at the point of time (t) of the release of the signal is marked and issued in highlighted manner. An independent claim is included for a device for requesting or preparing material in a production environment.

Description

The The invention relates to a method for requesting and / or providing of material in a production environment, comprising at least a workstation and a storage unit, wherein by a number of products to be manufactured Material in a given quantity is provided in at least one charge carrier, wherein after removal of the material from the charge carrier a signal triggered as a request for a material delivery becomes.

nowadays Methods are widely used in which a product is in succession following steps or workstations is made. At the workstations are or are each a human and / or a mechanical operator for one or more work steps provided, with a certain amount of different materials is used to finish the product. In the preparation of of a product becomes the respective one in the respective work station Material used, resulting in a regular replenishment is required.

From the DE 696 23 788 T2 For example, a method of manufacturing a product formed of a plurality of parts is known. In this case, at least two workstations are provided, wherein a type of individual parts is used in each case a workstation to create a semi-finished product, which is passed to the subsequent workstation. Each workstation is supplied with in this to be processed items, which are transported in containers. The number of items in the containers is always the same. The items are consumed, leaving the container until it is emptied at the workstation. A signal for subsequent delivery of the items is generated by means of the empty container. The generated signal is detected, triggering a re-delivery command. A new container is provided to the item consuming workstation.

there the method is based in particular on the so-called kanban principle. The kanban principle is a subsystem of a production control, especially just-in-time production. In doing so, in particular in series production low stocks in the individual Aimed at workstations. Short lead times and guaranteed Deadlines are other overarching goals. To this The purpose is the production in self-regulating control circuits to subdivided into processing material. With the help of so-called Kanbans (Japanese: map / board / slip) triggers the respective one Consumer an order with a predetermined amount and a specific order date. A producer or supplier of the material Brings these to the required date in a required installation quality to the customer. This is the so-called or pulling principle (pull principle).

Of the Invention is based on the object, a continuous synchronization need to ensure consumption and inventory in a production environment and a method improved over the prior art without the use of complex retrograde consumption calculations to have to.

The Task is according to the invention in terms of the method that in claim 1 and in terms of the device by the in Claim 14 specified features solved. Advantageous developments The invention are the subject of the dependent claims.

The inventive method for requesting and / or Provision of material in a production environment at least one workstation and at least one storage unit, based on a number of products to be manufactured of the respective Workstation material, for example, individual parts and / or assemblies, in a given amount in at least one charge carrier, for example a container in the form of a bucket or box becomes. After complete removal or processing of the Material from the charge carrier will at least be a signal triggered as a request for a material delivery. This designates the term production environment in particular a production site a series production, for example in the automotive industry. According to the invention, an available standing stock of material around the material provided in the charge carrier reduced, being one at the time of triggering the signal last production order marked system-technically and / or highlighted, in particular optically and / or acoustically is spent.

Thereby are advantageously a gross demand, a predicted Consumption as well as a stock of the still available Material determined at the time of the signal and synchronized. In a particularly advantageous manner can be determined by the method be how high the stock of available Material in the production environment is, with a deviation of the stock at most one content of a carrier is. This is a permanent, often with mistakes Affected inventory management is no longer required.

Based the synchronization at the time of triggering the Requirement of material becomes the up to then used material recorded as processed in an advantageous manner.

For this It is specifically intended that all in the production environment occurring processes, in particular those of a material flow, be recorded electronically, with all recorded operations be supplied to a data processing system. Thereby the production process becomes paperless in a particularly advantageous manner realized.

Thereby, that the last produced production order is marked and / or highlighted visually and / or acoustically, it is possible until the time the signal is triggered To determine material consumption retrograde and according to the real one Correct material consumption. The real material consumption is determined based on the capacity of the empty container.

The inventive method can on the one hand in a production environment with at least one workstation and On the other hand, they can also be applied across locations.

The new method does not determine the material consumption based on a retrograde consumption booking, but determines the material consumption from the contents of the "empty" containers, which are triggered by the KANBAN call. additionally can determine a difference in consumption for the determination of wastage and rejects between a real consumption on the basis of KANBAN (consumption-controlled Replenishment supply) and calculated consumption based on retrograde determination are determined.

additionally it is possible with the new procedure that is devoted Inventory after consumption posting at the production warehouse by a system recorded number of "full KANBANs" computationally and with the stock value after the consumption posting to compare or correct automatically. An elaborate, Continuous inventory control of delivery warehouse for a production can be omitted.

conditioned by existing order backlog or a present production plan the products to be manufactured become a gross requirement of the material determined. It is with the aid of, for example, a so called bill of material determines what amounts of material into a higher-level unit, in particular into a semi-finished product or in the product itself. The BOM describes a structured arrangement of material, in particular individual parts and / or assemblies required to manufacture a product are. From the through the BOM and the present Production plan calculated gross demand is particularly advantageous Way a net demand determined. The net demand is the demand on material that is not present in the storage unit. So will the net need from the gross amount minus the available determined material stock.

One respective carrier in which the requested material is provided is characterized in that this one Information about the transported in the carrier Material, its given quantity as well as the material carrying consuming workstation. Through a computer system All production orders and those for production orders necessary steps and the necessary Workstation planned. Additionally, those are in the workstations required parts from the parts list in the DV system known. By the "ready message" of a work process The parts installed in the workstation can be adjusted accordingly the BOM as spent on the production order Parts are booked. This is in the catchy literature described as a "retrograde booking". Through this Booking becomes the "stock" of the installed parts Reduced accordingly at the workstation and the need accordingly covered.

The inventive method can directly and / or Used in combination with a retrograde booking.

a) direct consumption booking

These Method is directly on the consumption booking. That triggered by the physically "empty container" Order signal for replenishment supply (pull principle) posts the in the "empty Container "previously provided amount as consumption. The completed operations up to the time of the signal and those in the parts lists for the operation Parts to be installed are marked as "installed" and may be booked on a separate "account" become. As a result, the demand is exactly at the time of consumption and synchronized with respect to the operation / workstation. It There is no retrograde posting! The physical consumption is the leading size in the consumption booking to reduce the stock. By the reference to the production order at the time of KANBAN becomes a permanent synchrony made to the needs. It is always only the real, physical consumption the previously delivered to the "empty container" Quantity booked. In the direct comparison of the finished Operations of the production orders booked Parts with physically used parts can be a fade or a Under-consumption are determined. In addition, the stock of the part at the workstation by a determination of the stock be corrected at the time of KANBAN. This will be described below.

b) Combination with retrograde consumption booking

The Basic principle corresponds to variant a).

To the Time of the KANBAN signal becomes a reference as in the variant a) produced for the production order at the corresponding workstation. Deviating from this variant is the retrograde consumption booking leader. Due to the retrograde consumption booking were or, if necessary, by postponing the feedback reduces the stocks of parts at the workstations and the demands. The new method becomes the time of the KANBAN signal determines the physical inventory at the workstation. The investigation this stock value is explained in section c). additionally becomes as in a) the time of the KANBAN at the workstation production order determined and the consumption based on the retrograde consumption calculation determined. Subsequently, will the system inventory in the computer system of the part at the workstation the physical inventory at the time of KANBAN and not yet Corrected retrograde amount. Then done A retrograde update results in the computer system of the physical exact inventory at the workstation.

c) Determination of physical inventory at the time of the KANBAN signal.

The Determination of physical inventory is for the variant b) mandatory.

requirement for the determination of an exact stock is the control by classical Kanban. Each part and workstation (KANBAN control loop) is preassigned Determines how many KANBANs (containers) to supply replenishment needed. In a computer system, KANBAN is at least KANBAN status "full" and "empty" detected. Is a load carrier physically empty at the workstation, so by triggering the KANBAN signal the corresponding KANBAN is set to "empty" in the system. Done yours Delivery to the workstation, then the corresponding KANBAN set to "full" again. The stock of the Workstation is determined by the sum of all quantities KANBAN's part of a workstation in full status at the time the KANBAN signal.

By a DV technical supplement is possible, too for classical summarized masses without KANBAN control one Determine stock value. This is done in a DV system in the background a Table led indirectly to the workstation standing container leads. According to a KANBAN control are all full containers with the appropriate quantities guided.

is the charge carrier is filled, the label stands as Information for the content. Is the charge carrier empty, the information stands for how much material it is to be filled up or for which material of the Workstation is to be supplied. In other words, it carries every empty load carrier is the complete information an order placement of a material delivery and thus the quantity for consumption booking.

The Workstation is in particular after triggering the signal in particular an entire production process with material in identical load carriers supplies, whereby additionally a confusion excluded can be.

embodiments The invention will be explained in more detail with reference to a drawing.

there shows:

1 schematically a production environment of a series production, wherein the production environment includes a number of workstations and a storage unit.

each other corresponding parts are in the figure with the same reference numerals Mistake.

In 1 is a production environment P, in particular a production line of a series production, which comprises a plurality of successive workstations A1 to A6, in each of which individual and / or several work steps are performed, and a storage unit L is shown.

In For example, in the present embodiment an assembly line of an automobile manufacturer shown, wherein a product to be manufactured P1 to P6 a subsequent Workstation A1 to A6 for processing, for example by means of an assembly line M is supplied. Here is the product P1 over time of a production process in the workstations A1 to A6 have been manufactured first.

At the respective workstation A1 to A6 is not at least one positioned operator, that of the workstation A1 to A6 processed product P1 to P6 processed.

Each work station A1 to A6 in the present embodiment preferably has an input unit I1 to I6 and an output unit O1 to O6, which are in particular connected to a central electronic data processing system DVS, whereby particularly preferably all performed in the production environment P operations, in particular those of a material flow electronically detectable. This allows the producti Onsprozess particularly preferably be carried out paperless.

The Input units I1 to I6 and the output units O1 to O6 can preferably also each as a unit, for example as a touch-sensitive screen, be formed.

The electronic data processing system DVS is about it also with an input unit I7 and an output unit O7 of the storage unit L connected. For example, the respective Input unit I1 to I7 and the respective output unit O1 to O7 by means of a wireless connection to the data processing system DVS coupled.

One Material requirement of the respective workstation A1 to A6 is based on an order entry, in particular an order backlog B or of an existing production plan. This is for example by means of a so-called BOM records which quantities of which material, for example individual parts and / or assemblies, into a higher-level unit, d. H. in one to be manufactured Product P1 to P6, received. The bill of materials is one structured arrangement of material used to manufacture a product P1 to P6 is required.

Especially preferred is a backlog B in the central data processing system DVS deposited. The material requirement recorded using order backlog B is referred to as the gross demand of the products to be produced P1 to P6.

In the storage unit L, for example, a buffer storage, is a material inventory MB available to ensure continuous production. One unavailable required material requirement, the Net Demand is calculated on the basis of gross demand minus of the available material stock MB.

The inventive method is based on the so Kanban principle, each workstation A1 to A6 the required material is provided consumption-oriented. For this purpose, identical, for example two, charge carriers LT1 and LT2 always uses an equal amount of in the respective one Workstation A1 to A6 contain material to be processed. A form of the charge carriers LT1 and LT2 becomes more advantageous Way selected depending on the material to be transported. For example, the charge carriers LT1 and LT2 be designed as a bucket, boxes or similar.

About that In addition, a respective charge carriers LT1 and LT2 for clear identification with an electronic, graphic and / or alphanumeric identifier provided. For this purpose, the Carrier LT1 and LT2, for example, with a label provided on which the to be transported, from the workstation A1 to A6 material to be processed, its predetermined amount and the corresponding workstation A1 to A6 is noted. Especially Advantageously, the label can also be provided with a barcode be that contains the above information. For example The LT1 and LT2 carriers can be scanned be, with the information about the input unit I1 to I7 are entered.

The inventive method is exemplary the workstation A4, which processes a material A closer explained. The workstation A4 is by means of the charge carrier LT1 provided the material A to be processed. For this purpose is the charge carrier LT1, for example, on the assembly line M positioned.

Of the provided at the workstation A4, not shown operator consumes the material A or emptied the carrier Complete LT1 by connecting it to the workstation A3 of the workstation A4 supplied product P3 is processed. If the charge carrier LT1 is completely emptied, is a signal as a request for a material delivery ML of the material A to this workstation A4 triggered. This is done by the operator, for example, via the Workstation A4 assigned input unit I4 the request the material delivery ML entered.

there For example, in the time when the material A is consumed is, an identical charge carrier LT2 with the required Material A of the workstation A4 provided. The charge carrier LT2 was especially during complete emptying filled in the workstation A4 in the storage unit L. The fact that the signal is triggered, the invention is accurate at a time t of triggering the signal the material inventory MB in the storage unit L advantageously by the amount of emptied charge carrier LT1 reduced. This is in particular from the operator, for example via the input unit I4 the entered material requirement as a signal for inventory reduction used. Here, the available stock of material MB continuously electronically recorded, with a deviation of the material inventory MB especially advantageous at most a lot of the content of the charge carrier LT1, for example is located on a transport path to the workstation A4.

Farther the procedure provides that at the time t of triggering of the signal the last manufactured product P1 to P3, in particular P3 or the last order made in the IT system.

By marking and / or highlighting the last production order made can be particularly advantageous consumption of the material A to exactly be determined at the time t. That until the time t used material A can be particularly advantageous on the basis of the parts list be determined by means of a retrograde consumption determination and is preferably detected as consumed or processed.

Summarized is added by the method according to the invention the time t of triggering the signal or the request for material delivery ML a in the storage unit L available standing material stock MB, a future material requirement (Gross and net requirements) as well as a past material consumption synchronized in an advantageous manner, whereby with regard to further finished products P1 to P6 exact planning of production control and thus a self-adjusting material inventory management can be carried out.

Further The procedure provides that when disposition of the material A faulty material A is recorded and the material stock MB is also reduced by this amount. Has the material inventory MB a minimum quantity, the so-called safety stock, becomes a material delivery requirement using the kanban principle ML1 triggered to internal and / or external suppliers. Based on the request of the material delivery ML1, it is possible also a consumption-oriented one for internal and / or external suppliers To enable production.

P

production environment

L

storage unit

M

assembly line

B

order backlog

DVS

Data processing system

A1 to A6

workstation

P1 to P6

to finished products

I1 to I6

input unit

O1 to O6

output unit

A

material

ML

Requirement material supply

ML1

Requirement material supply

LT1, LT2

charge carrier

MB

material inventory

t

time

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 69623788 T2 [0003]

Claims (14)

Method for requesting and / or providing material (A) in a production environment (P), comprising at least one workstation (A1 to A6) and a storage unit (L), wherein, based on a number of products (P1 to P6) to be manufactured, material ( A) in a predetermined amount in at least one charge carrier (LT1, LT2) is provided, wherein after removal of the material (A) from the charge carrier (LT1, LT2) a signal as a request for a material delivery (ML) is triggered, characterized in that an available material inventory (MB) is reduced by the material (A) provided in the charge carrier (LT1, LT2) and a product (P1 to P6) last produced at the time (t) of triggering the signal is marked and / or highlighted becomes. Method according to claim 1, characterized in that that until the time (t) of triggering the signal consumed material (A), which is in the charge carrier (LT1, LT2) has been provisioned as being processed. Method according to claim 1 or 2, characterized that all processes of a material flow in the production environment (P) be recorded electronically. Method according to claim 3, characterized that all electronically recorded operations a data processing system (DVS) are supplied. Method according to one of claims 1 to 4, characterized in that one until the time (t) of triggering the signal current consumption of the material (A) determined retrograde can be. Method according to one of claims 1 to 5, characterized in that based on the products to be manufactured (P1 to P6) a gross requirement is determined. Method according to Claim 6, characterized that based on the gross demand and the available Material Stock (MB), a net requirement is determined. Method according to one of claims 1 to 7, characterized in that a respective workstation (A1 to A6) with material (A) in identical charge carriers (LT1, LT2). Method according to one of claims 1 to 8, characterized in that the one or more charge carriers (LT1, LT2) each loaded with the same amount of material (A) will or will be. Method according to one of claims 1 to 9, characterized in that a respective charge carrier (LT1, LT2) with an electronic, graphic and / or alphanumeric Flag is provided. Method according to claim 10, characterized in that a respective charge carrier (LT1, LT2) is characterized in such a way is that this information about the in the charge carrier (LT1, LT2) transported material (A), its amount and about the workstation (A1 to A6) consuming the material (A). Method according to claim 11, characterized in that that the charge carrier (LT1, LT2) of the corresponding, the Material (A) processing workstation (A1 to A6) via the information is assigned. Method according to one of claims 1 to 12, characterized in that a number of to be filled Carriers (LT1, LT2) based on the products to be manufactured (P1 to P6) is determined. Apparatus for carrying out the method according to one of claims 1 to 13, comprising at least one Workstation (A1 to A6) and a storage unit (L), using a number of products to be manufactured (P1 to P6) material (A) in a given amount in at least one charge carrier (LT1, LT2), wherein an output unit (O1 to O9) is provided for outputting a signal by means of which Removal of the material (A) from the charge carrier (LT1, LT2) a signal as a request for a material delivery (ML) can be triggered is provided with a data processing system (DVS), the all electronically recorded processes of a material flow processed and by means of the one available Material inventory (MB) in the load carrier (LT1, LT2) provided material (A) is reducible, with one at the time (t) the triggering of the signal last produced production order (P1 to P6) marked on an output unit (O1 to O9) and / or is shown highlighted.