JP2000015530A - Synchronizing production directing system of vehicle production line - Google Patents

Abstract

PROBLEM TO BE SOLVED: To carry out a synchronizing production securely by securing the assembling and transmitting lead times of parts. SOLUTION: When an SBS controller PLC to detect the car body passing outputs a car body discriminating information by the SBC out 6a of a main line, a synchronizing production directing computer finds the shortest time necessary to move the car body from a PBS-in 4b to a PBS-out 4a depending on the car body discriminating information, and the car body filling condition and the car body delivery order of a PBS 4, and compares the sum of the shortest time, and the car body moving time from the PBS-out 4a to the AXL assembly process of a vehicle assembly line 5, with the lead time necessary to assemble the AXL at a subline 2, and to transmit the AXL from the subline 2 to the AXL assembly process of the vehicle assembly line 5, and when the sum is shorter than the lead time, it makes the subline 2 start the assembly of the AXL at once, and when the sum is longer than the lead time, it makes the subline 2 start the assembly of the AXL when it is known that the car body passed the PBS-in 4b from the car body discriminating information output from the PBS controller PLC to detect the car body passing at the PBS-in 4b of the main line, after that.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a main line having a vehicle body painting line, a PBS (Painted Body Storage or Painted Body Storage) and a vehicle assembly line in order, and a part to be assembled to a vehicle body on the vehicle assembly line. The present invention relates to a synchro production instruction system for synchronizing parts assembly on a sub-line of a production line of a vehicle such as an automobile with a sub-line to be assembled with vehicle assembly on a main line.

[0002]

2. Description of the Related Art FIG. 9 shows an example of a vehicle production line for producing automobiles. The vehicle production line includes a main line 1 and a sub line 2, where the main line 1 is composed of a vehicle body painting line 3 and a PBS 4. And vehicle assembly line 5
The main line 1 includes a vehicle body painting line 3 on a vehicle body assembled on a vehicle body assembly line (not shown).
The painted vehicle body exiting the vehicle body painting line 3 is sorted and stored in a plurality of storage lanes arranged in parallel with the PBS 4, and various parts are assembled on the vehicle body assembly line 5 on the vehicle body exiting the PBS 4. Assembling the vehicle.
In the sub-line 2, an AXL (axle) as a part to be assembled to the vehicle body on the vehicle assembly line 5 of the main line 1 is assembled.

In the conventional synchro production instruction system, a computer (not shown) for instructing the AXL assembly work on the sub-line 2 is used to synchronize the AXL assembly with the vehicle assembly on the main line 1 in FIG. As shown by the solid arrow, the PBS out 4a which is the outlet of the PBS 4
And the information indicating the specification of the vehicle body that has passed through the vehicle, starts the assembly of the AXL for the vehicle body that has passed through the sub-line 2, and the vehicle body is the AXL group of the vehicle assembly line 5. AXL assembly is completed at subline 2 before the process
L is transmitted to the AXL assembly process of the vehicle assembly line 5.

[0004]

However, in such a conventional synchro production instruction system, if the AXL assembling step is changed to a step before the vehicle assembling line 5 by changing the assembling procedure, the assembling and delivery of AXL is performed. Lead time is short, so that synchro production cannot be made in time and inventory must be kept.

In order to eliminate such inconvenience, the above-mentioned computer is controlled by a PBS as shown by a dashed arrow in FIG.
Receiving the information that the vehicle body has passed through the PBS-in 4b, which is the entrance of the vehicle 4, and the information indicating the specifications of the vehicle body that has passed the PBS-in 4b,
It is conceivable to start the assembly of the AXL for the vehicle body that has passed through the sub-line 2. However, even in this case, the time required for the vehicle body to pass through the PBS 4 is the same as that of the PBS 4.
It depends on the vehicle filling condition and the vehicle payout order, so if the PBS 4 is vacant or if the vehicle is in the early payout order, the vehicle will pass through it in a short time, so that shortage of lead time cannot be solved. There was a problem.

[0006]

SUMMARY OF THE INVENTION An object of the present invention is to provide a synchro production instruction system which advantageously solves the above-mentioned problems. The instruction system is
Parts on the sub-line of a vehicle production line comprising a main line having a vehicle body painting line, a PBS (painted vehicle body storage) and a vehicle assembly line in order, and a sub-line for assembling parts to be assembled to the vehicle body on the vehicle assembly line In a synchronous production instruction system for synchronizing assembly with vehicle assembly on the main line, a PBS-in passage information output means for detecting a vehicle body passing through the PBS entrance of the main line and outputting identification information of the vehicle body passing therethrough A vehicle body painting line front position passing information output means for detecting a vehicle body passing a predetermined position in front of the vehicle body painting line on the main line and outputting identification information of the vehicle body passing therethrough; When the position passing information output means outputs the identification information of the passing vehicle body, the identification information of the vehicle body and the Based on the vehicle filling state of the PBS and the vehicle payout order, the minimum time required for the vehicle to move from the entrance to the exit of the PBS, which is the minimum time required for the PBS to pass, is determined. The sum of the post-PBS movement time required for the movement of the vehicle body up to the assembly process of the parts of the vehicle assembly line,
Compared to the lead time required for assembling the part on the sub-line and delivering the part from the sub-line to the part assembly process of the vehicle assembly line,
If the sum of the BS shortest time and the post-PBS movement time is shorter than the lead time, the sub-line is immediately started to assemble the parts, and the sum of the PBS shortest time and the post-PBS movement time is the sum of the above. If it is longer than the lead time, then, based on the identification information of the vehicle body passed by the PBS-in passage information output means, when it is determined that the vehicle body has passed through the PBS entrance, the sub-line to the component And a component assembly start instructing means for starting the assembly of the components.

In such a system, the PBS-in passage information output means detects a vehicle passing through the PBS entrance of the main line and outputs identification information of the vehicle passing therethrough. The information output means detects a vehicle body passing a predetermined position in front of the vehicle body painting line of the main line, outputs identification information of the vehicle body passing the predetermined position, and the parts assembly start instructing means outputs the vehicle body painting line preceding position. When the information output means outputs the identification information of the passing vehicle body, the PB of the vehicle body is determined based on the identification information of the vehicle body, the filling state of the vehicle body of the PBS, and the vehicle payout order.
P is the shortest time required to move from the entrance to the exit of S
The shortest time to pass through BS is calculated, and the shortest time to pass through PBS and P
PB required for the movement of the vehicle body from the exit of BS to the process of assembling the parts to be assembled on the sub-line of the vehicle assembly line
The sum of the post-S travel time and the lead time required to assemble the part on the sub-line and deliver the part from the sub-line to the assembly process of the part on the vehicle assembly line is calculated as If the sum of the post-PBS movement time is shorter than the lead time, the subline is immediately started to assemble the part, and if the sum of the PBS shortest time and the post-PBS movement time is longer than the lead time, After that, based on the identification information of the vehicle body passed by the PBS-in passage information output means, it was found that the vehicle body previously detected by the vehicle body painting line front position passage information output means came to the PBS entrance and passed there. At this time, the sub-line is started to assemble parts.

Therefore, according to the synchro production instruction system of the present invention, a vehicle passing a predetermined position before the vehicle painting line of the main line is detected, and the PB at that time is detected.
The time required for the vehicle body to pass through the PBS and arrive at the parts assembly process of the vehicle assembly line is determined from the vehicle body filling status and the vehicle dispensing order of S, and the determined time is the lead time for subassembly and delivery in the subline. If the time is shorter than the lead time, the assembly of the parts is started immediately on the sub-line immediately after passing through the predetermined position before the body painting line. Since the sub-line starts to assemble parts when passing, even if the assembly process of the parts to be assembled in the sub-line is changed to the former process of the vehicle assembly line by changing the assembly procedure, the above lead time can be secured. As a result, synchronized production can be performed reliably, and a large number of parts stocks are prevented from being issued too early due to an instruction to start assembling parts. Obtained, of requiring the parts inventory without almost no it is possible to enjoy the advantages of the synchronous production.

In the present invention, the predetermined position at which the vehicle position passing information output means for detecting a vehicle passing before the vehicle body painting line detects the vehicle body is located at an outlet of the vehicle body storage before painting immediately before the vehicle body painting line on the main line. In this case, the increase or decrease in the time required to pass through the PBS and arrive at the parts assembly process of the vehicle assembly line due to the difference in the passage time of the PBS is substantially equal to or smaller than the increase or decrease. Since it can be adjusted by the transit time of the car body painting line, which is a line just before the PBS, which is slightly longer, the lead time can be secured even when the PBS transit time is the shortest, and when the PBS transit time is the longest However, it is possible to effectively prevent a situation in which a large number of parts stocks are accumulated due to a part assembly start instruction being issued too early.

[0010]

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a block diagram showing an embodiment of a synchro production instruction system for a vehicle production line according to the present invention, and FIG. 2 is a vehicle production line for automobile production to which the synchro production instruction system of the embodiment is applied. FIG. 3 is a block diagram showing processing executed by a synchro production instruction computer of the synchro production instruction system of the embodiment.

The vehicle production line shown in FIG. 2 has a main line 1 and a sub line 2 like the one shown in FIG.
The main line 1 includes an SBS (silver body storage, that is, vehicle body storage before painting) 6, a vehicle body painting line 3, and a PBS (painted vehicle body storage) 4.
And the vehicle assembly line 5 are sequentially provided. On the main line 1, the vehicle bodies assembled on the vehicle body assembly line (not shown) are sorted and stored in a plurality of storage lanes arranged in parallel with the SBS6, and the vehicle exits the SBS6. The car body is painted on the car body painting line 3, and the painted car body exiting the car body painting line 3 is sorted and stored in a plurality of storage lanes arranged in parallel with the PBS4, and the car body assembly line is provided on the car body leaving the PBS4. At step 5, the vehicle is assembled by assembling various parts. In the sub-line 2, an AXL (axle) as a part to be assembled to the vehicle body on the vehicle assembly line 5 of the main line 1 is assembled.

On the other hand, the synchro production instruction system of this embodiment shown in FIG. 1 includes a production management computer 11, a synchro production instruction computer 12, and an SBS control PLC (programmable logic) which are interconnected via a network 10. Controller) 13 and PBS control PLC 14
, A production instruction printer 15 and a shipping instruction printer 16, wherein the SBS control PLC 13
Detects the vehicle body passing through the SBS out 6a, which is the exit of the vehicle 6 and transmits the identification information of the vehicle body that has passed (the vehicle body passing number including the vehicle management number), and transmits the vehicle body to a plurality of storage lanes of the SBS 6. The operation of the conveyor of the SBS 6 is controlled so as to sort and pay out the vehicle bodies from the storage lanes, and the PBS control PLC 14 controls the PBS.
The vehicle body passing through the PBS-in 4b, which is the entrance of the vehicle 4, and the PBS-out 4a, which is the exit of the PBS 4, are detected, and the identification information of the vehicle body (the vehicle passage result including the vehicle management number) is transmitted. The operation of the conveyor of the PBS 4 is controlled so that the vehicle bodies are distributed to the plurality of storage lanes and the vehicle bodies are paid out from the storage lanes.

And a production management computer here.
11 receives the vehicle passing results in the SBS out 6a from the SBS control PLC 13 and receives the vehicle passing results in the PBS in 4b and the PBS out 4a from the PBS control PLC 14, and manages the main line 1 based on them. In order to control the PBS control PLC 14 and output an assembling instruction list to the vehicle assembly line 5, the synchro production instruction computer 12 sends the SBS out 6a, PBS in 4b and P
The vehicle passing results at the BS out 4a are received, the processing shown in FIG. 3 is performed based on the vehicle passing results, and the production instruction printer 15 instructs the assembly of the AXL in the sub-line 2 and the shipping instruction printer 16. Indicates the shipment of AXL from the sub-line 2.

That is, a synchro production instruction computer
12, as shown in FIG. 3, after performing a process 21 of receiving the actual vehicle passing results in the SBS out 6 a, the PBS in 4 b and the PBS out 4 a from the production management computer 11, among them, the PBS in 4 b and the PBS out 4 b 4a, a shipping instruction process 23 for summarizing the vehicle passage actual data 22 and outputting the PBS out actual data of the PBS in / out actual data 22 by the shipping instruction printer 16.
To instruct the AXL to be assembled to the vehicle body that has passed the PBS out 4a from the completed product dump 2a of the sub-line 2 shown in FIG.

The synchro production instruction computer 12 further outputs the PB of the PBS in / out result data 22.
Using the S-in performance data, the same PBS tracking processing 24 as that of the production management computer 11 is performed to generate PBS tracking data (data indicating which vehicle body is stored at which position from the front of which storage lane of the PBS 4) 25. Then, the PBS tracking data 25 and the same PBS dispensing condition table as that of the production management computer 11 (the dispensing condition of the vehicle body from the PBS for equalizing the number of vehicle types and equalizing the work load on the vehicle assembly line). A process 27 for calculating the PBS shortest transit time is performed by using the table 26), and the PBS shortest transit time data 28 is created as needed.

Further, the synchro production instruction computer 12
After performing the above-mentioned vehicle passing result reception processing 21, the data 29 of the vehicle passing result in the SBS out 6a of the received data is summarized, and the SBS out result data 29
The production instruction data management process 30 is performed on the vehicle body that has passed through the BS out 6a to create the production instruction data 31 as shown in FIG.
Lead time data 32 for AXL production on sub-line 2 and delivery of AXL from sub-line 2 to AXL assembly process on vehicle assembly line 5 on main line 1, and vehicle assembly from PBS out 4a on main line 1. Line 5
The production instruction timing determination process 34 shown in FIG. 5 is performed based on the data 33 of the time required for the vehicle body to move to the AXL assembling process.

In the production instruction timing determination process 34,
First, in step 41, the production instruction point of AXL is PB
Whether S-in 4b is in time is determined by PBS shortest transit time and P
It is determined whether or not the sum of the time required for the vehicle body to move from the BS out 4a to the AXL assembling step of the vehicle assembly line 5 is smaller than the lead time for production and delivery of AXL. ), The sum of the PBS shortest transit time and the time required for the vehicle to move from the PBS out 4a to the AXL assembly process of the vehicle assembly line 5 is smaller than the lead time for AXL production and delivery. In this case, the process proceeds to step 42, where the production instruction point of AXL is set to PBS-in 4b, while, as shown in FIG.
If the sum of the PBS shortest transit time and the time required for the vehicle to travel from the PBS out 4a to the AXL assembly process of the vehicle assembly line 5 is equal to or greater than the lead time for AXL production and delivery, Then, the process proceeds to step 43, in which the AXL production instruction point is set to the SBS out 6a in order to secure the above-mentioned lead time, and in step 44, the production instruction data cutout process 36 described later is started. In addition,
This production instruction data cutout processing 36 is also performed by the PBS
Using the PBS in result data of the in / out result data 22, the vehicle is also activated when the vehicle passes the PBS in 4b.

Thus, the synchro production instruction computer 12
Is a process for extracting production instruction data when the vehicle passes through the SBS out 6a and when the vehicle passes through the PBS in 4b.
36, the data 35 indicating the production instruction point created in the production instruction timing determination processing 34, the production instruction data 31 as shown in FIG. 4, and the AXL production instruction data conversion table 37 as shown in FIG. Is used to execute the production instruction data cutout process 36 shown in FIG.

In the production instruction data cutout process 36,
First, in step 51, the activation source is SBS out 6a or PBS.
In 4b, that is, it is determined that the vehicle has passed and the process has been started, and if the activation source is SBS out 6a, the production instruction point for the passed vehicle is determined in the next step 52. It is obtained from the production instruction point data 35.

In a succeeding step 52, it is determined whether or not the production instruction point is the SBS out 6a.
If not, the processing of this step is SBS out 6a.
Since the vehicle has been started by passing the vehicle and the vehicle is still in the vicinity of the SBS out 6a, the subsequent steps are skipped and the process ends. On the other hand, if the starting source is the PBS-in 4b in step 51 and if the production instruction point is the SBS out 6a in step 53, the vehicle management number of the vehicle passing through the starting source is used as a key in step 54. The production instruction data 31 is searched for the data of the vehicle body that has passed the activation source, and in a succeeding step 55, the production instruction management flag of the data of the vehicle body is turned ON. However, since the production instruction has already been issued for the vehicle body with the PBS-in 4b and the production instruction management flag turned ON when the vehicle has already passed the SBS-out 6a, the production instruction management flag is set to O here.
Set to FF.

In the last step 56, the AXL data in the production instruction data 31 for the vehicle body of the vehicle management No. for which the production instruction
Using the L production instruction data conversion table 37, the data is converted into production instruction data 38 for assembling AXL for the vehicle body that has passed the activation source.

After that, a computer for instructing synchro production
12 is the AXL production instruction data 38 created in this way.
To the sub-line 2 by the production instruction printer 15,
AX for the vehicle body that has passed its activation source in subline 2
Instruct the start of assembly of L.

Therefore, in this embodiment, the PBS control PLC 14 corresponds to the PBS-in passage information output means, and the SBS control PLC 13 corresponds to the vehicle body painting line front position passage information output means.
Reference numeral 12 corresponds to a component assembly start instruction means.

Thus, according to the synchro production instruction system of this embodiment, the vehicle body passing through the predetermined position 6a in front of the vehicle body painting line 3 of the main line 1 is detected, and the vehicle filling state of the PBS 4 and the vehicle body at that time are detected. From the payout order, the time required for the vehicle body to pass through the PBS 4 and arrive at the AXL assembling step of the vehicle assembly line 5 is obtained, and the obtained time is shorter than the lead time of AXL assembly and delivery in the sub-line 2 Immediately after passing the predetermined position 6a before the body painting line 3,
Start the L assembly, and if the time obtained above is longer than the lead time, then the vehicle
Since the AXL assembly is started on the sub-line 2 when passing through 4b, even if the assembly process of the AXL to be assembled on the sub-line 2 is changed to the process at the front of the vehicle assembly line 5 due to the change of the assembly procedure, the above lead time Can be secured,
Synchro production can be performed reliably, and AX
It is possible to prevent a large number of AXL stocks from accumulating due to the L assembly start instruction being too early, and it is possible to have almost no AXL stock.

Further, according to the synchro production instruction system of this embodiment, the predetermined position at which the SBS control PLC 13 as the vehicle body painting line front position passage information output means detects the vehicle body passing is located on the vehicle painting line 3 of the main line 1. Since it is the exit 6a of the SBS 6 immediately before, the vehicle assembly line 5 passing through the PBS 4 and having the A
The increase or decrease in the time to arrive at the XL assembling process can be adjusted by the passage time of the vehicle body painting line 3 which is a line immediately before the PBS 4 which is substantially equal to or slightly longer than the increase / decrease range. Is the shortest, the lead time can be secured, and even when the passing time of the PBS 4 is the longest, the AXL assembly start instruction is too early and the A
It is possible to effectively prevent a large number of XL stocks from accumulating.

Although the present invention has been described based on the illustrated examples, the present invention is not limited to the above-described examples. For example, the parts assembled on the sub-line may be other than the above-mentioned AXL. If the output means detects the passage of the vehicle body before the vehicle painting line,
A location other than the exit 6a of the BS 6 may be used.

[Brief description of the drawings]

FIG. 1 is a block diagram showing one embodiment of a synchro production instruction system for a vehicle production line according to the present invention.

FIG. 2 is a configuration diagram showing a vehicle production line for producing an automobile to which the synchro production instruction system of the embodiment is applied.

FIG. 3 is a block diagram showing processing of an AXL assembly start instruction and a shipping instruction executed by a synchro production instruction computer of the synchro production instruction system of the embodiment.

FIG. 4 is an explanatory diagram showing file contents of production instruction data created by a synchro production instruction computer in the above processing.

FIG. 5 is a flowchart showing a procedure of a production instruction timing determination process executed by a synchro production instruction computer in the above process.

FIG. 6 is an explanatory diagram showing a production instruction timing determination process executed by the synchro production instruction computer in the above process.

FIG. 7 is an explanatory diagram showing the contents of an AXL production instruction data conversion table used by the synchro production instruction computer in the above processing.

FIG. 8 is a flowchart showing a procedure of production instruction data cutout processing executed by the synchro production instruction computer in the above processing.

FIG. 9 is a configuration diagram showing a vehicle production line for producing an automobile to which a conventional synchro production instruction system is applied.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Main line 2 Sub line 2a Dump of finished AXL product 3 Body painting line 4 PBS 4a PBS out 4b PBS in 5 Vehicle assembly line 6 SBS 6a SBS out 11 Production control computer 12 Synchro production instruction computer 13 SBS control PLC 14 PBS control PLC 15 Production Instruction Printer 16 Shipping Instruction Printer

Claims (2)

[Claims] 1. A main line (1) having a body painting line (3), a PBS (4), and a vehicle assembly line (5) in order;
A synchronizing production instruction system for synchronizing part assembly on the sub line with vehicle assembly on the main line of a vehicle production line comprising a sub line (2) for assembling parts to be assembled to a vehicle body on the vehicle assembly line; Detecting a vehicle body passing through the entrance (4b) of the PBS and outputting identification information of the vehicle body passing through the entrance (4b).
A BS-in passage information output means (14), a vehicle body painting line for detecting a vehicle body passing a predetermined position (6a) in front of the vehicle body painting line of the main line and outputting identification information of the vehicle body passing therethrough; Position passing information output means (13), when the vehicle body painting line front position passing information output means outputs the identification information of the vehicle body that passed, the identification information of the vehicle body, the vehicle filling status of the PBS and the vehicle payout order, The minimum time required for the vehicle to move from the entrance to the exit (4a) of the PBS, which is the minimum time required for passing the PBS, is determined based on the minimum time required for the vehicle to pass through the PBS and the exit of the PBS. The sum of the post-PBS movement time required for the movement of the vehicle body up to the assembling step is determined by assembling the parts on the sub-line and setting the parts on the vehicle assembly line from the sub-line. If the sum of the shortest PBS transit time and the post-PBS travel time is shorter than the lead time compared to the lead time required to deliver the part to the process, immediately begin assembling the part on the subline. If the sum of the PBS shortest pass time and the post-PBS travel time is longer than the lead time, the vehicle body is then identified based on the identification information of the vehicle body passed by the PBS-in passage information output means. Part assembly start instructing means (12) for starting assembly of the part on the sub-line when it is determined that the part has passed the PBS entrance
And a synchro production instruction system for a vehicle production line. 2. The vehicle-body-painting-line-position-passing-information output unit detects the passing vehicle body at a predetermined position at which an outlet (6a) of a pre-painting vehicle body storage (6) immediately before the vehicle-body painting line on the main line. The synchronized production instruction system for a vehicle production line according to claim 1, wherein: