JP2000280146A - Production method in fms including heat treatment facility, and fms using same production method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently machine a work requiring heat treatment in FMS in accordance with the delivery date. SOLUTION: A heat treatment facility to apply heat treatment to workpieces, an ante-process facility to apply an ante-process before the heat treatment to the workpieces, a post-process facility 40 to apply a post-process after heat treatment to the workpieces, and an automated storage and retrieval system 52 to store the workpieces after heat treatment in the heat treatment facility 30 as partially fabricated items are provided, if time till a timing when manufacture is to be completed to inputted order information is long or short to a specified time is determined, material workpieces are machined from the ante- process facility to an order with the longer time till the timing when manufacture is to be completed than the specified time, and the partially fabricated items stored in the automated storage and retrieval system are machined in the post-process facility 40 to an order with the shorter time till the timing when manufacture is to be completed than the specified time.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production method in an FMS including a heat treatment facility, and an FMS using the production method.
In particular, the present invention relates to a technology capable of efficiently processing a work requiring heat treatment.

[0002]

2. Description of the Related Art A flexible production system generally referred to as an FMS is composed of a plurality of NC machine tools and an automatic work called an AGV that can move between the machine tools and carry in / out a work to / from these machine tools. A transport device;
The control device controls all the machine tools in the system or a necessary machine tool in accordance with a machining program corresponding to each work. As such a production system, there are known various systems dedicated to square workpieces, dedicated to round workpieces, and various systems for processing both square workpieces and round workpieces.

[0003] However, there has not yet been proposed a system in which a heat treatment step is incorporated in such a production system. This is because many difficulties, including the following typical difficulties encountered when incorporating a heat treatment step into the FMS, remain unresolved. One of the difficulties is that the heat treatment process requires a longer time in comparison with the machining time of the work in each machine tool, and therefore, the stagnation of the work in the heat treatment process makes it difficult to adjust the production schedule. It is in. Another difficulty is that a practical measure for increasing the processing efficiency in the heat treatment step has not been realized.

[0004] Further, another difficulty is that when a work is supported by a common holder in both the heat treatment step and the machining step, which are exposed to a high temperature in the heat treatment furnace, the holder becomes thermally deformed in the heat treatment step. However, this is related to the problem that the workpiece cannot be machined to the desired machining accuracy in the machining process. In the manufacturing process of various parts, it was not possible to incorporate a heat treatment process into automatic processing equipment such as FMS due to the above-mentioned difficulties. For this reason, the automatic equipment of the previous process, the heat treatment equipment and the automatic equipment of the post-process are configured independently, and the heat processing of the work processed by the equipment of the pre-process is performed by the heat treatment equipment, and then input to the equipment of the post-process. I am trying to do it.

[0005]

However, in the above-mentioned conventional example, since three independent steps, ie, a pre-process, a heat treatment process, and a post-process, cannot be performed in all processes. In addition, since the heat treatment process takes a long time and the number of work that can be put into the heat treatment furnace at one time is limited, the three processes of the pre-process, the heat treatment process, and the post-process must be efficiently operated. Is difficult. Furthermore, since the heat treatment conditions are different when the material of the work is different, it is necessary to perform a heat treatment that requires a long time for each material of the work, which is also a factor that hinders the efficiency improvement, and is a problem particularly in a high-mix low-volume production. Becomes Accordingly, an object of the present invention is to provide a production method in an FMS including a heat treatment step suitable for small-volume production of various kinds, which can eliminate the drawbacks of the conventional example described above and can efficiently process a work requiring heat treatment. And an FMS using the production method.

[0006]

Means for Solving the Problems In order to solve the above-mentioned problems, the structure of the first invention of the present application is as defined in claim 1. According to the configuration of the first aspect of the invention, first, it is determined whether the order information is longer or shorter than a predetermined time before the time when the production should be completed, that is, whether the order is a long delivery order or a short delivery order. Next, for a long delivery order, a schedule for processing the material work from the pre-processing equipment is created, and for a short delivery order, a schedule for processing the semi-finished product stored in the automatic warehouse by the post-processing equipment is created. A work is manufactured according to the created schedule. As a result, it is possible to respond to an order with a short delivery time in an FMS including a heat treatment that requires a long processing time.

Further, the structure of the second invention is as described in claim 2. With the configuration of the second aspect, the first aspect
In addition to the operation according to the configuration of the invention, if there is a margin in the heat treatment capacity of the heat treatment equipment when performing the heat treatment for the order with a long delivery date, a schedule for replenishing semi-finished products is created using the margin. This makes it possible to efficiently manufacture a long delivery order and a short delivery order by efficiently using the heat treatment capacity of the heat treatment equipment.

[0008] Further, the structure of the third invention is as described in claim 3. According to the configuration of the third aspect, the production planning device firstly determines whether the time until the time to complete the manufacturing with respect to the input order information is longer or shorter than a predetermined time, that is, whether the order is a long delivery order or a short delivery date. Determine if it is an order. Next, for the long delivery order, create a long delivery schedule to process the material work from the pre-process equipment,
For a short delivery order, a short delivery schedule is created in which semi-finished products stored in the automated warehouse are processed by post-processing equipment.
The control device controls the transport device or another device in accordance with the long delivery schedule and the short delivery schedule to manufacture a work. As a result, it is possible to respond to an order with a short delivery time in an FMS including a heat treatment that requires a long processing time.

Further, the structure of the fourth invention is as described in claim 4. With the configuration of the fourth aspect, the third aspect
Along with the operation of the configuration of the invention, as a long delivery schedule, first, a work to be mounted on the heat-resistant basket is determined in the heat-treating step, and a heat-treatment schedule is created. A return box for the work to be mounted in the previous process is determined and a pre-processing schedule is created. Further, the order in which the returnable boxes loaded with semi-finished products and stored in the automatic warehouse are transported to the post-processing equipment valley is determined, and a short delivery schedule is created. The control device controls the transport device according to each created schedule, and the material work is processed by the pre-processing equipment, heat treatment equipment, and post-processing equipment for long delivery orders, and semi-finished products for short delivery orders. The workpiece is processed in post-processing equipment. As a result, it is possible to realize an FMS capable of responding to a short delivery order despite including a heat treatment facility that requires a very long time for processing.

Further, the structure of the fifth invention is as described in claim 5. With the configuration of the fifth aspect, the fourth aspect
In addition to the operation of the invention, the production planning apparatus adds a heat treatment schedule for replenishing semi-finished products when the heat treatment schedule has room, and creates a pre-process schedule based on the heat treatment schedule with the replenishment of semi-finished products. As a result, it is possible to realize an FMS that can efficiently manufacture a long delivery order and a short delivery order using the heat treatment capacity of the heat treatment equipment without waste.

Further, the structure of the sixth invention is as described in claim 6. With the configuration of the sixth aspect, the fourth aspect
Along with the operation according to the fifth aspect of the present invention, a plurality of works are mounted on a returnable box and conveyed to the pre-process facility. Each work is processed in the pre-process of heat treatment, and then the plurality of works are processed again. Individual works are mounted on a returnable box and carried out of the pre-process equipment. Then, in the heat treatment facility, the work is transshipped from the return box to the heat-resistant basket, and further heat-treated in a state in which a plurality of heat-resistant baskets are stacked. For this reason, F can be produced more efficiently.
MS can be realized.

Further, the structure of the seventh invention is as described in claim 7. With the configuration of the seventh aspect, the fourth aspect
The control device controls not only the transport device but also the automatic warehouse and the palletizing device together with the operation according to the configuration of any one of the sixth to sixth inventions. Thus, in accordance with the created long delivery schedule and short delivery schedule, entry / exit control in the automatic warehouse and transfer control by the palletizing device are performed.

[0013]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows the F according to the present invention.
FIG. 2 shows a part of the MS, and FIG. 2 shows another part of the FMS according to the present invention. In addition, FIG. 1 and FIG. 2 have an overlapping part. 3 shows details of a part of FIG. 2, FIG. 4 shows each step of the FMS according to the present invention, and FIG. 5 shows a control system of the FMS according to the present invention.

FIG. 6 shows a cross-sectional structure of an example of a workpiece processed by the FMS 1 according to the present invention. In FIG. 6, reference numeral 80 denotes a turret punch press die.
1, a punch body 82, and a punch guide 83. For each of these three types of parts, various types of parts having different shapes and sizes are machined.
Here, 81a is a punched hole of the die 81. Reference numeral 83a denotes a punched hole of the guide 83.
If the shape of a is circular, it is called a round, and if it is polygonal, it is called a shape.

Referring to FIGS. 1 to 5, an FMS (Flexible
The main parts of Manufacturing Systen (1) are material pick-up processing equipment 10, pre-processing equipment 20, heat treatment equipment 30, post-processing equipment 40, automatic warehouses 51, 52, 53, and AGV (Automated).
Guided Vehicle) 61, 62, palletizing device 70
And a production planning device 2, a host computer 4, a process management server 5, a pre-processing line management device 6a, a post-processing line management device 6b, automatic warehouse management devices 7a, 7b, 7c, an AGV controller 8a, 8b, a palletizer management device 9, and the like.

Each of these computers is connected by a LAN (Local Area Network) as shown in FIG. Then, the host computer 4 inputs order information from an order management computer (not shown), creates production instructions for the pre-process and the post-process, and registers it in the process management server 5. The production planning device 2 reads out the manufacturing instruction from the process management server 5, creates a schedule for each process, and registers it in the process management server 5. Thereby, the pre-processing line management device 6a, the post-processing line management device 6b,
The automatic warehouse management devices 7a, 7b, 7c, the AGV controllers 8a, 8b, and the palletizer management device 9 respectively follow the schedule registered in the process management server 5,
Pre-process equipment 20, post-process equipment 40, automatic warehouse 51, 5
2, 53, AGV 61, 62 and palletizing device 7
The transfer head 73a of 0 is controlled.

As shown in FIG. 4A, the bar material 90 is cut by a circular saw or a band saw in the material taking process equipment 10, and is stored in a return box 85 by a transfer robot. Then, the return box 85 in which the cut bars 90 are stored is stored in the automatic warehouse 51. Here, the return box 85 is a box for transporting a plurality of works, and is configured to be able to store a plurality of works at a predetermined position (hereinafter referred to as a box address) by a partition or the like. In the pre-process facility 20, first, AG
The V61 takes out the return box 85 (containing the cut round bar 90) from the automatic warehouse 51 and transports it. Note that A
The GV 61 moves along a guide wire 61a provided on the floor. Further, a charging station (ST) 61x for charging the AGV 61 is disposed adjacent to the guide wire 61a.

Next, in the punch body pressing line 24,
The base material carry-in ST24a passes through the cut round bar 90 conveyed by the AGV 61, removes it from the box 85, and carries it into the punch body press-contact line 24. As shown in FIG.
Since the ID 85a is attached to each returnable box 85, information about the work 80 in the returnable box 85 can be obtained by searching the ID 85a using a sensor (not shown). The cut-in round bar 90 that has been loaded is sequentially pressed into the crimping machine 24b, the induction annealing machine 24c, the deep hole processing machine 24d,
Processed at 24e. The members processed in the punch body press-contact line 24 are put into a return box 85 by the material unloading ST24f, returned to the AGV 61, and transferred into the punch body line 22 of the pre-process facility 20.

The die material (cut bar 90) conveyed from the automatic warehouse 61 by the AGV 61 is supplied to the die line 21 of the pre-process facility 20 by the work loading ST21a.
Similarly, the guide material (cut bar 90) conveyed from the automatic warehouse 61 by the AGV 61 is carried into the guide line 23 of the pre-process facility 20. The die material carried into the die line 21
e, 21f, and selectively conveyed by the NC lathe 21b,
At 21c, machining center 21d is processed as shown in FIG. 4 (b), packed into returnable box 85, and carried into automatic warehouse 52. In FIG. 4, R indicates a round and S indicates a shape.

Similarly, the punch body material carried into the punch body line 22 is processed by the punch body line 22, packed in a return box 85, and stored in the automatic warehouse 52.
It is carried in. The time required in the pre-processing step by the pre-processing equipment 20 is about 2 minutes on average for processing one workpiece 80. (Specifically, the die is about 1.8 minutes, the punch body is about 2 minutes, and the guide is about 2.7 minutes.) The time required for the post-processing described below is the time required for the pre-processing. Is almost the same as

Next, the heat treatment equipment 30 is
The workpiece processed in and stored in the automatic warehouse 52 is heat-treated as follows. The automatic warehouse 53 is a warehouse that stores a heat-resistant basket 86, supplies the heat-resistant basket 86 to the palletizing device 70 as needed, and collects the heat-resistant basket 86 from the palletizing device 70. The automatic warehouse 53 includes a transfer head 53a, a guide rail 53b, a shelf 53c, and a basket storage conveyor 5.
3d and a basket shipping conveyor 53e.
Here, the heat-resistant basket 86 is a box for holding and transporting a plurality of works at the time of heat treatment, and is configured to be able to store a plurality of works at predetermined positions (addresses in the box) by partitioning or the like.

The transfer head 53a is a heat-resistant basket 86
And can be moved along the guide rail 53b, and furthermore, can be moved vertically. For this reason, the transfer head 53a
Can store the heat-resistant basket 86 on the multi-stage shelves 53c, and can remove the heat-resistant basket 86 from the shelves 53c. The basket receiving conveyor 53d receives the heat-resistant passet 86 at the processed part (work) transfer position 53y and carries it into the automatic warehouse 53. The basket shipping conveyor 53e processes the heat-resistant basket 76 in the automatic warehouse 53 before processing. It is transported to the part (work) transfer position 53x.

First, the AGV 62 palletizes a returnable box 85 (containing a work (in this case, a die material, a punch body material and a guide material)) stored in the automatic warehouse 52 along a guide wire 62a. To 70. The work quality check ST62x is provided near the guide wire 62a.

The palletizing apparatus 70 includes overhead rails 71 and 72, a tray circulation conveyor 73, a transfer head 73a, and conveyors 74 and 75. Transfer head 73a moving along overhead rail 72
Is transferred to the heat-resistant basket 86 at the pre-heat treatment part transfer position 53x. Here, the returnable box 85 and the heat-resistant basket 86 are configured to be able to store the same number of works, and when the works are transferred, the transfer is performed using the same box address. On the other hand, the transfer head 73a that moves along the overhead rail 71 receives the heat-treated work from the heat-resistant basket 86 at the processed part transfer position 53y, and transfers the work to the return box 85 carried by the conveyor 74.

The tray circulating conveyor 73 includes the transfer head 7
The tray 87 carrying the heat-resistant basket 86 carried by 3a is carried. 73x is a tray circulation conveyor 73
It is the step-down position in. Here, the term “stacking” refers to stacking the heat-resistant basket 86 containing the work before heat treatment on the tray 87 as shown in FIG.
Conversely, the step-down means to lower the heat-resistant basket 86 containing the heat-treated work from the tray 87. In order to perform this stacking and unstacking, the transfer head 7
3a not only can grip and transport one work piece but also can grip and transport the heat-resistant basket 86.

The heat treatment equipment 30 includes a heat treatment transport shuttle 31, a guide rail 31a, a cleaning device 32, a quenching device 33, tempering devices 34 and 35, and a cooling device 36. The heat treatment transport shuttle 31 receives the tray 87 on which the heat-resistant basket 86 containing the work is placed from the tray circulation conveyor 73, moves in the direction of the arrow 31b along the guide rail 31a, and sequentially cleans the work.
2. Conveyed to the quenching device 33, the tempering devices 34 and 35, and the cooling device 36. The workpieces heat-treated by the heat treatment equipment 30 are returned to the tray circulation conveyor 73 transported by the heat transport shuttle 31 for each tray 87.

The time required for one heat treatment (the above "stacking")
To "separating") takes about 10 hours. In addition,
Specifically, the required time of one heat treatment differs depending on the material of the work. For example, about 11.6 hours for SKD, about 16.8 hours for SKH, and about 9.6 hours for SCM. The heat-treated work is loaded into the return box 85 as described above, transported by the conveyor 74 and the AGV 62, and stored in the automatic warehouse 52. Thereafter, the heat-treated work is transported by the AGV 62 and carried into the post-processing equipment 40.

The post-processing equipment 40 includes a die line 41, a punch body line 42, and a guide line 43. In the die line 41, the shape work loading device 4 is provided.
A 1x and round work loading device 41y are provided. As shown in FIG. 4D, the work carried in by the shape work carry-in device 41x into the redi line 41 is selectively moved by the self-propelled robot 41j to the work cooling device 41a, the pin press-in device 41b, the external grinding device 41c, and the like. It is transported to the inner laboratory device 41d and processed. After that, the workpiece is selectively discharged by the self-propelled robot 41k to the electric discharge machine 41e,
After being conveyed and processed by the inspection and marking device 41f, the cleaning device 41g, and the Hiraken device 41h, it is sent to the unloading table 41i.

Similarly, the round work loading device 41y
The work carried into the redi line 41 is processed in the same manner as described above to form a round die 81. Similarly, the work carried into the punch body line 42 is processed into a shape punch pod 82 or a round punch body 82. Similarly, the work carried into the guide line 42 is processed into a shape guide 83 or a round guide 83.

Here, the overall flow of the production process according to the embodiment of the present invention will be briefly described as follows. The production planning device 2 creates a schedule of only the post-process for an order whose delivery date is within a predetermined time (for example, 24 hours) (hereinafter referred to as a short delivery date order) according to the delivery date from the order information, and the delivery date is Orders longer than the specified time (hereinafter,
It is called a long delivery order. For ()), a schedule from the previous process is created. The schedule of the pre-process is a heat treatment schedule in the heat treatment equipment 30 (batch information and stacking information described later).
Created based on If there is room for heat treatment, replenishment work (automated warehouse 52 for short delivery order)
(Semi-finished product) in the previous process.

The work pre-processed according to the schedule of the previous process is carried into the automatic warehouse 52. The pre-processed work in the automatic warehouse 52 is transferred from the return box 85 to the heat-resistant basket 8 according to the schedule of the heat treatment process.
6 and heat treated. The work after the heat treatment is returned to the return box 85 and carried into the automatic warehouse 52. The work of the long delivery order with the pre-process and heat treatment completed is transported to the post-process in the same order as the schedule of the pre-process, and the post-process is performed, and the work of the short delivery order in which only the post-process schedule is created Is carried out from the automatic warehouse 52 to the subsequent process according to the schedule of the subsequent process. The work with a short delivery time and the work with a long delivery time are alternately carried out from the automatic warehouse 52 to a subsequent process.

FIG. 7 is a flowchart showing the processing of the host computer 4. In step 10, the host computer 4 acquires product order information from the order management computer (not shown). In step 12,
The host computer 4 determines the shipping date for each product from the received order information, and determines whether the time from the determination to the shipping date is within 24 hours. If the determination result is NO, which means that the order is for a long delivery date, a production instruction for the previous process is created in step 14. On the other hand, if the result of the determination is YES, it means that the order is for a short delivery date.
The production instruction of the post-process for the semi-finished product work is created.

FIG. 8 is a flowchart showing a schedule creation process in the preceding process in the production planning device 2. At step 20, the production planning device 2
, And registers it in the process management server 5 as pre-process order information. In step 22, a work ID is set for each work from the pre-process order information, and in-line work instruction information in the pre-process equipment 20 and the post-process equipment 40 is created and registered in the schedule management server 5. .

At step 24, information on stacking (basket information, stacking information, heat treatment batch information) is read. The heat treatment batch information is a heat treatment schedule for one day as shown in FIG. 14 (because the heat treatment conditions differ depending on the material) (in the example of FIG. 14, two times for each of the three types of materials, that is, six times a day). Heat treatment is performed.). The stacking is a stacking pattern in each heat treatment batch as shown in FIG. 15 and information on a basket in the pattern, and the basket information indicates a type of work that can be mounted on the basket. These pieces of information are set in the production management device 2 in advance according to the production amount.

In step 26, the stacking layout is performed.
Stacking allocation is to develop the above information as shown in FIG. In step 28, a work allocating process (flow chart in FIG. 9) in the preceding process is performed. In step 30, the replenishment work allocation processing (the flowchart of FIG. 10) is performed, and the processing ends.

The flowchart shown in FIG. 9 is a subprogram corresponding to step 28 in FIG. 8, and shows the work allocating process (1) in the pre-process schedule creation process. In step 40, the stacking allocation information in FIG. 16 is sorted and rearranged by the batch number of heat treatment and the type of returnable box as shown in FIG. The work assignment in the pre-process manufacturing instruction is performed for each type of returnable box (corresponding to the basket) used in the stacking pattern specified in each heat treatment batch. Therefore, the stacking allocation information is sorted in these units, and thereafter, the work allocation processing is performed using the sorted information. For this reason, according to the schedule of the heat treatment, the schedule is made in the order of the material of the work → the heat treatment batch order → the stacking order → the type of the returnable box 85. Can be set the priority of the schedule.

In step 42, it is determined whether or not the work has been allocated to all the returnable boxes 85 in the stacking layout.
The processing of 8) is repeated for each returnable box 85 in the sort order of the returnable return boxes 85. In step 44, a work instruction mountable on the return box 85 is obtained from the in-line work instruction information. In step 46, the work ID for the work instruction acquired in step 44 is searched.

In step 48, the work ID searched in step 46 is assigned to the stacking information. In particular,
In the first row of the table shown in FIG. 17, the above-mentioned priorities (workpiece material → heat treatment batch order → stacking order → return box 8)
According to the fifth stack type, the basket of the first stacking order in the heat treatment of the first batch of the material SKH (the stacking pattern in FIG. 15 indicates that the type of the basket 86 is “Die 1 / 2-R
・ S ”), a work instruction that can be mounted on the returnable box type“ Woo 1 ”is acquired from the in-line work instruction information, a work ID corresponding to the work instruction is searched, and the searched work ID is obtained. It is associated with the address in the box in the return box “C-1”. Since the addresses in the boxes of the returnable box 85 and the basket 86 correspond one-to-one, the work is assigned to the returnable box “Woo 1” and the basket “Die 1 / 2-R
• Same as the work assignment in "S".

Therefore, information on the stacking (basket information, stacking information, heat treatment batch information) and each basket 86 in the heat treatment performed based on this information are described.
Is equivalent to the heat treatment schedule. Here, the return box 85 to which the work ID is assigned
Are sorted in the heat treatment batch order and the stacking order, the sorted order of the returnable boxes 85 and the work ID assigned to each returnable box 85 correspond to the pre-process schedule.

The flowchart shown in FIG. 10 is a subprogram corresponding to step 30 in FIG. 8, and shows a supplementary work allocating process in the preprocess schedule creation process. In the case of an order with a short delivery time that requires shipment within 24 hours, the production instruction from the previous process cannot meet the shipment date and time, and in such a case, a semi-finished product work in the automatic warehouse 52 is allocated (post-process in FIG. 11). See schedule creation process). Therefore, a stock of semi-finished products is required in the automatic warehouse 52. If there is room for the heat treatment of the heat treatment equipment 30, this semi-finished product for stock (replenishment work) is allocated as follows. .

First, in step 50, it is determined from the stacking allocation information whether there is an empty returnable box 85, that is, whether there is a returnable box 85 in which no work has been allocated in step 28. If the determination result in step 50 is YES, this means that there is room for 6 batches of heat treatment per day by the heat treatment equipment 30.
Proceeds to step 52, and the result of determination in step 50 is NO
In the case of, it means that there is no room for heat treatment,
The process ends without allocating the replenishment work.

In step 52, it is determined whether or not there is a free return box 85 in the automatic warehouse 52. The return box 85 here is a return box for storing semi-finished products in the automatic warehouse 52, and the result of the determination in step 52 is YE
In the case of S, this means that when a semi-finished work is created by allocating a replenishment work (by performing pre-processing and heat treatment), the semi-finished work can be stocked in the automatic warehouse 52. If the determination result at 52 is NO, it means that there is no room in the automatic warehouse 52, and the process ends without allocating the supplementary work.

The determination in both steps 50 and 52 is YE
In the case of S, the processing from step 54 to step 62 is repeated for each empty returnable box 85 in the stacking layout searched in step 50, and the process is repeated for all empty returnable boxes 85 in the stacking layout. When the processing of 56 or less is completed, the determination in step 54 becomes YES, and the replenishment work assignment processing ends.

In step 56, it is determined whether or not the empty empty box 85 corresponding to the empty empty box 85 in the target stacking layout is in the automatic warehouse 52. That is, when a semi-finished work is made by allocating a replenishment work to the empty returnable box 85 in the stacking layout, it is determined whether or not there is an empty returnable box 85 of a type capable of storing the semi-finished work in the automatic warehouse 52. is there. this is,
Although it is known that there is a free return box 85 in the automatic warehouse 52 in step 52, when the replenishment work is allocated, the type of return box 85 in the stacking layout and the type of the free return box 85 in the automatic warehouse 52 are allocated. Is different, the semi-finished product work cannot be stocked in the automatic warehouse 52. Therefore, if the determination in step 56 is NO, the replenishment work is not assigned to the empty returnable box 85 in the target stacking layout, and the process returns to step 54 to target the empty returnable box 85 in the next stacking allocation. The process is performed.

If the determination in step 56 is YES, that is,
When the empty returnable box 85 corresponding to the empty returnable box 85 in the target stacking layout is in the automatic warehouse 52, the process proceeds to step 58. In step 58, the number of the corresponding empty returnable box 85 in the automatic warehouse 52 retrieved in step 56 is set as the number of the returnable box 85 in the stacking layout, and a reservation flag is set in the information in the automatic warehouse 52. . This is because the empty return box 85 in the automatic warehouse 52
Is a flag indicating that a reservation has been made for replenishment work allocation. By setting this reservation flag, it is prevented that the work is extracted again in step 56.

In step 60, step stacking and in-line work instruction information are created. That is, the heat treatment batch number and the stacking order are acquired from the information of the empty returnable box 85 in the stacking layout, the work corresponding to the stacking layout information is allocated, and the in-line work instruction information for the allocated work is created. I do. For the work allocated in the stacking process in the pre-process schedule creation process of FIG.
In-line work instruction information is created in step 22. However, in-line work instruction information is created in step 60 for a supplementary work.

In step 62, the work assigned in step 60 is additionally registered in the previous process order information. This also applies to step 2 for the work that has been allocated in the pre-process schedule creation process in FIG.
Although the pre-process order information is registered at 0, the pre-process order information is created in step 62 for the replenishment work.

FIG. 11 is a flowchart showing a process of creating a post-process schedule in the production planning device 2. In step 70, the production planning device 2 receives the post-process manufacturing instruction from the host computer 4, and registers it in the process management server 5 as post-process order information. Next, the processing of steps 72 to 76 is repeated for each work instruction of the post-process order information, and when the processes of steps 74 and 76 are completed for all the work instructions of the post-process order information, at step 78 The setting process is performed, and the post-process schedule creation process ends. In step 74, a returnable box 85 equipped with a semi-finished product work in the automatic warehouse 52 corresponding to the target work instruction is searched. Performs work assignment processing.

The flowchart shown in FIG. 12 is a subprogram corresponding to step 76 in FIG. 11, and shows the work allocating process (2) in the post-process schedule creation process. The processing after step 80 is the same as that in FIG.
All the returnable boxes 85 (not limited to one) retrieved in one step 74 are processed on a returnable box basis.
First, in step 80, it is determined whether or not the processing for all of the returnable boxes 85 searched in step 74 has been completed.
When the processing for all returnable boxes 85 is completed, the work allocating processing ends.

The processing from step 82 onward is performed for all works in the target return box 85 in units of works. In step 82, it is determined whether or not the processing for all the works in the target return box 85 has been completed. When the processing for all the works has been completed, the process proceeds to step 92,
The number of works in the return box 85 is updated, that is, the number of works in the return box 85 is updated by subtracting the number of works allocated in step 88 described later from the current number of works in the return box 85. In step 84, it is determined whether or not the target work has been allocated. This is a determination as to whether or not the work has already been allocated in the previous work allocation process. If the work has already been allocated, the process returns to step 82 to process the next work, and If not, the process proceeds to step 86 to allocate the target work.

In step 86, work information of the target work is read. This work information is stored in step 60 of FIG.
And reads the work information of the target work from the in-line work instruction information based on the work ID of the target work. Then, in step 88, the target work is allocated according to the read work information. The work allocation referred to here is to update the post-process order information registered in step 70 in FIG. 11 based on the work ID of the target work and the work information read in step 86 as a specific process. That is, it means that the work ID of the semi-finished work in the automatic warehouse 52 is associated with the post-process order information. Then, this work allocation processing and FIG.
The setting process of the delivery order corresponds to creation of a post-process schedule.

In step 90, it is determined whether or not the number of allocations has reached the number of orders.
Then, the process is performed for the next work, and if the number of allocations has reached the number of orders, the process proceeds to step 94. Here, the number of orders is the number of works in the work instruction when the target returnable box 85 is searched in step 74 of FIG. 11, and when the number of allocations reaches this number of orders, the target work instruction is Means that the creation of the schedule for the post-process has been completed. The update of the number of works in the return box 85 in step 94 is the same as the processing in step 92 described above.

The flowchart shown in FIG. 13 is a sub-program corresponding to step 78 in FIG. 11, and is a process for setting the order when unloading the boxes 85 from the automatic warehouse 52 to the post-processing equipment 40. First, at step 100, the retrieval order of the return box 85 in the return box 85 in the automatic warehouse 52, which has already been determined in the retrieval order, is retrieved. Next, a return box 85 in the automatic warehouse 52
, A returnable box 85 in which the work allocation process of FIG. 12 has been performed and the return order of which is not yet determined is retrieved. Then, the processing of steps 104 and 106 is performed on the returnable box 85 retrieved in step 102.

In step 106, the order of delivery is set for the returnable box 85 retrieved in step 102 in accordance with a predetermined priority order. In the setting of the delivery order, a delivery order obtained by adding 1 to the latest delivery order searched in step 100 is set. Then, in step 104, when it is determined that the setting of the delivery order has been completed for all of the returnable boxes 85 searched in step 102, the process ends.

The return box 85 in which the delivery order is determined in this way is conveyed to the post-processing equipment 40 by the AGV 62 based on the return order, and the return box 85 in which the release order is set. Are only those that have a work with a short delivery order. In contrast to the work of the short delivery date order, the work of the long delivery date order is based on the schedule created in the pre-process schedule creation process in FIG.
It is transported from the automatic warehouse 52 to the post-processing equipment 40.

As described above, in the automatic warehouse 52, the return box 85 to be transported to the post-process equipment 40 according to the pre-process schedule, and the return box 85 to be transported to the post-process equipment 40 according to the post-process schedule (order of delivery). Both return boxes 85 are present. For this reason, the two are connected in any order in the post-processing equipment 4.
It is necessary to set a rule of whether or not to carry to zero. This rule can be changed depending on the order status. For example, if the ratio of the long delivery order to the short delivery order is almost the same, the two are alternately transferred from the automatic warehouse 52 to the post-processing equipment 40.
It may be set to be transported to

In the above-described embodiment, the production planning device 2, the host computer 4, the process management server 5, the pre-processing line management device 6a, the post-processing line management device 6b,
The automatic warehouse management devices 7a, 7b, 7c, the AGV controllers 8a, 8b, and the palletizer management device 9 are each composed of a computer such as a personal computer. The schedule created by the production planning device 2 is registered in the process management server 5, and Is read from the process management server 5 to control each device. However, the present invention is not limited to this. Some of these functions are collectively controlled by a single computer. You may do so.

Further, in the above-described embodiment, the AGV 61 is provided between the material removal process equipment 10 and the pre-process equipment 20.
The AGV 62 passes between the automatic warehouse 52 and the heat treatment equipment 30 and between the automatic warehouse 52 and the post-processing equipment 40 with a box 85.
Between the pre-process facility 20 and the automatic warehouse 52
Although it is configured to directly transport the return box 85 regardless of the V, the present invention is not limited to this, and various types of transport means can be used in consideration of the length of the transport distance and the like.

According to the above-described embodiment, a schedule from the previous process is created for an order with a long delivery time, but for an order with a short delivery time, a semi-finished workpiece that has been subjected to pre-processing and heat treatment in advance is created. Since only the schedule of the post-process is prepared, it is possible to incorporate the heat treatment equipment into the FMS, and it is possible to respond to the order with a short delivery time while providing the heat treatment equipment that requires a long time for the processing.

In addition, if the heat treatment for a long delivery order is prioritized, and there is room for the heat treatment capacity during this heat treatment,
A schedule for replenishing semi-finished products has been added, so effectively using heat treatment equipment that takes time to process,
Both long delivery orders and short delivery orders can be manufactured efficiently. Furthermore, by making the schedule of the pre-process based on the schedule of the heat treatment process based on this heat treatment schedule, it is possible to efficiently operate the heat treatment process that requires a long time for the treatment.

[0061]

According to the first aspect of the present invention, a schedule for processing a material work from a pre-process facility is prepared for a long delivery order, and a semi-finished product stored in an automatic warehouse for a short delivery order. Since a schedule for processing is manufactured by post-processing equipment, it is possible to respond to an order with a short delivery time in an FMS including a heat treatment equipment that requires an extremely long time for processing.

Further, according to the second invention, in addition to the effect of the first invention, a schedule for replenishing semi-finished products is prepared when the heat treatment capacity of the heat treatment equipment has room, so that the heat treatment By utilizing the capacity without waste, long-order orders and short-order orders can be efficiently manufactured.

Further, according to the third aspect of the present invention, not only can the heat treatment equipment requiring a very long time for processing be incorporated into the FMS, but also an efficient FMS that can respond to short delivery orders can be realized. Can be.

Further, according to the fourth invention, together with the effect of the third invention, first, a heat treatment schedule is created as a long delivery schedule, and a pre-processing schedule is created based on this heat treatment schedule. In addition to the effects, even if there is a large time difference between the processing time by the pre-process equipment and the heat treatment time by the heat treatment equipment, efficient production can be performed by minimizing the stagnation of the work and the stop time of the equipment.

Further, according to the fifth aspect, in addition to the effect of the fourth aspect, it is possible to efficiently manufacture long-order and short-order orders by efficiently using the heat treatment capacity of the heat treatment equipment. it can. Further, since a plurality of heat-resistant baskets are heat-treated collectively in a stacked state, an FMS capable of more efficient production can be realized.

Further, according to the sixth invention, in addition to the effect of the fourth or fifth invention, since a plurality of heat-resistant baskets are heat-treated collectively in a stacked state, more efficient production is achieved. Can be realized.

Further, according to the seventh aspect, in addition to the effect of any one of the fourth to sixth aspects, not only the transport device but also the automatic warehouse and the palletizing device are controlled according to the long delivery schedule and the short delivery schedule. Therefore, it is not necessary to newly create a schedule for an automatic warehouse or a palletizing device.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram showing a part of an FMS according to the present invention.

FIG. 2 is an explanatory diagram showing another part of the FMS according to the present invention.

FIG. 3 is a detailed view of a part of FIG. 2;

FIG. 4 is an explanatory diagram showing each step of the FMS according to the present invention.

FIG. 5 is an explanatory diagram showing an FMS control system according to the present invention.

FIG. 6 is a cross-sectional view illustrating an example of a workpiece processed by the FMS according to the present invention.

FIG. 7 is a flowchart illustrating a production method according to the present invention.

FIG. 8 is a flowchart showing a pre-process schedule creation process according to the present invention.

FIG. 9 is a flowchart showing a work allocating process (1) in FIG. 8;

FIG. 10 is a flowchart showing a replenishment work allocating process in FIG. 8;

FIG. 11 is a flowchart illustrating a post-process schedule creation process according to the present invention.

FIG. 12 is a flowchart showing a work allocation process (2) in FIG. 11;

FIG. 13 is a flowchart illustrating a setting process of a delivery order in FIG. 11;

FIG. 14 is a table showing a daily schedule of heat treatment according to the present invention.

FIG. 15 is a table showing stacking information according to the present invention.

FIG. 16 is a table showing stacking allocation information according to the present invention.

17 is a table in which the stacking assignment information shown in FIG. 16 is sorted by the batch number and the same returnable box.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 FMS 2 Production planning apparatus 20 Pre-processing equipment 30 Heat treatment equipment 40 Post-processing equipment 52 Automatic warehouse 61, 62 AGV 70 Palletizing equipment 85 Returning box 86 Basket

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Yoshio Tsuruta 1-1-1, Asahi-cho, Kariya-shi, Aichi Toyota Machine Works Co., Ltd. (72) Inventor Kenji 1-1-1, Asahi-cho, Kariya-shi, Aichi Prefecture Toyota Machine Works Co., Ltd. (72) Inventor Hiroyuki Tsusaka 1-1-1, Asahi-cho, Kariya-shi, Aichi Toyota Machine Works Co., Ltd. (72) Inventor Satoshi Inami 3546-1, Tsukahara, Minamiashigara, Kanagawa F RA22 RA23 RB14 RB23 RB27 RB32 RE07 RH05 RJ01 RJ10 RK28 RL13 4K038 AA03 BA01 CA01 DA03 EA03 FA02

Claims (7)

[Claims] 1. A heat treatment facility for performing a heat treatment on a work, a pre-process facility for performing a work in a pre-process of the heat treatment on the work, and a post-process facility for performing a work in a post-process of the heat treatment on the work And an automatic warehouse for storing a workpiece heat-treated by the heat-treating equipment as a semi-finished product.
Judge the length of the time until the time to complete the production with respect to the input order information with respect to a predetermined time, and set the time until the time to complete the production to the order longer than the predetermined time. On the other hand, for the order in which the time until the time to complete the production is shorter than a predetermined time, the semi-finished product stored in the automatic warehouse is processed in the post-process. A production method in FMS, wherein a schedule for processing in equipment is created, and a work is manufactured according to the created schedule. 2. A schedule for replenishing the semi-finished product when there is room in the heat treatment capacity for an order longer than the predetermined time until the time when the production in the heat treatment facility is to be completed is completed. Item 4. The production method in FMS according to Item 1. 3. A heat treatment facility for performing heat treatment on a plurality of works mounted on a heat-resistant basket, a pre-process facility for performing a pre-process of the heat treatment on the work, and the heat treatment on the work. A post-process facility for performing post-process processing, a return box mounting a work that has been processed in the pre-process of the heat treatment by the pre-process facility, and a return pass mounting the work that has been heat-treated by the heat treatment facility. An automatic warehouse for storing boxes; and transporting the return box between at least the pre-processing equipment and the automatic warehouse, between the automatic warehouse and the heat treatment equipment, and between the automatic warehouse and the post-processing equipment. A conveying device, a palletizing device for transferring the work between the return box and the heat-resistant basket, and a time until the time when the production should be completed with respect to the input order information. Judging means for judging the length with respect to a fixed time, and a long delivery date for creating a schedule for processing a material work from the preceding process equipment for an order in which the time until the time when the production should be completed by the judging means is longer than the predetermined time. Schedule creation means, and a schedule for processing the work which has been heat-treated in the heat treatment equipment stored in the automatic warehouse as a semi-finished product in the post-processing equipment for an order in which the time until the time to complete the production is shorter than a predetermined time. An FMS comprising: a production planning device having a short delivery schedule creating means for creating; and a control device for controlling at least the transport device according to a schedule created by the production planning device. 4. The long delivery schedule creating means creates a heat treatment schedule including determining a work to be mounted on the heat resistant basket at the time of the heat treatment based on the order information, and creates a heat treatment schedule based on the heat treatment schedule. In this heat treatment schedule, a pre-process schedule is created including determining a return box for mounting a work to be mounted on the heat-resistant basket. 4. The FMS according to claim 3, wherein a post-process schedule is created including determining an order in which the returnable boxes mounted and stored in the automatic warehouse are transferred to the post-process equipment by the transfer device. 5. The long delivery schedule creating means adds a heat treatment schedule for replenishing the semi-finished product when the heat treatment schedule created based on the order information has a margin, and adds the heat treatment schedule to the added heat treatment schedule. The FMS according to claim 4, wherein the pre-process schedule is created based on the schedule. 6. The heat treatment equipment for performing heat treatment in a state in which a plurality of heat resistant baskets are stacked, wherein the heat treatment schedule includes a request number for stacking the heat resistant baskets in the heat treatment equipment. The equipment performs processing on each of the plurality of works mounted and carried in the return box, and mounts the processed work on the return box and unloads the work. The FMS according to claim 4 or 5, further comprising an order of loading the boxes into the pre-process facility. 7. The control device according to claim 4, wherein the control device controls the automatic warehouse and the palletizing device.
7. The FMS according to any one of claims 1 to 6.