JP2001001237A - Manufacture of plural kinds of products and construction of production system therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce the short-time stop, a failure time and the tooling loss by manufacturing products in co-operation with an automization process by reassembling a plurality of semi-automatic processes corresponding to kinds of products. SOLUTION: The work study and review of work formation on the work specified as the manual work in a step ST4 are executed (step ST7). Relating to the work specified as the work to be automated in a step ST6, the semi-automatic machine design is executed for automation (step ST8). The judgement on a view point of whether these works are efficient or not, is executed on the basis of a result of the work study and review of work formation in the step ST7 and a result of the semi-automatic machine design in the step ST8 (step ST9). When they are judged to be not efficient, the process is fed back to the step ST7 or the step ST8 again for re-studying, and the verification on the cost merit is executed only on the work judged to be efficient (step ST10).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a plurality of types of products and a method of constructing a production system thereof. The present invention relates to a manufacturing method for manufacturing a plurality of types of products, which can be shortened and further facilitates layout change depending on types, and a method for constructing a production system thereof.

[0002]

2. Description of the Related Art As an example of a conventional manufacturing process for manufacturing a plurality of types of products, an assembly process of a lithium ion battery will be described as an example.

[0003] In the conventional lithium ion battery assembling process, for the same type of battery, fully automatic devices are connected in a cascade by a conveyor. And the lithium ion battery is automatically assembled mechanically and completed.

As shown in FIG. 5, the steps of assembling such a lithium-ion battery actually vary depending on the type of lithium-ion battery, but the steps disclosed herein are one of these. It is an example. The structure of the assembly process of the lithium ion battery includes an elastic body supply process 10, an element insertion process 11, a lead welding process 12, a lid temporary fixing process 13
, A lid welding step 14, an EL injection step 15, and an injection port sealing step 16.

[0005] In an elastic body supply step 10, an electrode element 30, an elastic body 31, and a stopper tape 32 are supplied as components.
A subassembly 3 in which an elastic body 31 for securing appropriate adhesion between the electrode element 30 and a can into which the electrode element 30 is inserted is fixed to the electrode element 30 using a jig A by using a fixing tape 32.
Complete 3

Next, the process proceeds to an element inserting step 11, where a can 34 is provided as a part, and the can 3 is
4. The electrode element 30 assembled in the elastic body supplying step 10
The subassembly 33 in which the elastic body 31 and the elastic body 31 are integrated with the stopper tape 32 is inserted into the can 34.

In the lead welding step 12, the sealing case 35
And the lid 36 are provided as parts, and the sealing case 35 is inserted into the can 34 using the jig C, and is fitted. After that, the lead is positioned on the positive electrode of the lid 36 and welded to the lid 36, The lid 36 is fitted into the can 34 while bending the lead.

In the lid temporary fixing step 13, the lid 36 is temporarily fixed using the jig D, and the process proceeds to lid welding in the lid welding step 14. In this lid welding step 14, the can 34 and the sealing case 35
Seamlessly welded and sealed around the EL, EL (electrolyte)
The process moves to the injection step 15. In this EL injection step 15,
The electrolytic solution EL is supplied, and the electrolytic solution EL is injected into the can 34.

In the inlet sealing step 16, a sealing ball 37 is supplied as a component, and the inlet into which the electrolyte EL is injected is sealed using the sealing ball 37. Thereafter, although not shown, the process proceeds to an inspection process via a cleaning / drying process, and the assembly is completed.

[0010] Although there are actually parts that are difficult to automate depending on the components assembled in this way, even for those parts that are difficult to automate, there is a need for a balance in automation as a whole. It is designed to automate things.

Further, there are some lithium ion batteries having different sizes even though the assembly process of the lithium ion batteries is the same. Such a situation is dealt with by performing tooling on a necessary part of the assembly process.

[0012]

However, the above-described conventional methods of manufacturing a plurality of types of products, for example, lithium ion batteries, have the following problems.

First, if the assembly process is completely automated, different types of products cannot be flowed in the order of the processes, and a plurality of production lines must be prepared, resulting in a large investment cost and a low operating rate. There is a problem of doing.

Second, since parts of the assembling process, which are difficult to automate, are also automated depending on the parts, there are many troubles due to short-time stoppages and breakdowns, which lowers the operation rate and determines whether parts are present. Since it is necessary to provide a device with an automatic check function for checking, the cost of the device is high, and it is necessary to arrange personnel with specialized knowledge, thereby increasing the cost of the entire assembly process. There is.

Third, when the assembly process is the same but the product size is different, tooling is performed to cope with the problem. However, the number of tooling points including the part feeder increases, and it takes a long time to switch parts and adjust. There is a problem that it costs.

Accordingly, in an assembling process including a process that cannot be completely automated, it is possible to improve productivity by reducing short-time stoppage, failure time and tooling loss, and to suppress costs generated in the assembling process. Have challenges to do.

[0017]

SUMMARY OF THE INVENTION The present invention is, as a main structure for solving the above problems, a manufacturing method for manufacturing a plurality of types of products, and has a part for automatically manufacturing the products. An automated process, comprising a plurality of movable semi-automated processes with a built-in semi-automated machine, wherein the semi-automated processes are recombined with each other in accordance with the type of the product to produce a product in cooperation with the automated process. It is like that.

As another main configuration, the work corresponding to the product type is analyzed as to which work is suitable for the work that can be automated or the work that is manual, and the work that can be automated is handled. Design a semi-automatic machine, perform a manual work analysis based on a standard time for the work to be manually performed, and then calculate these efficiencies using the results of the work by the semi-automatic machine and the manual work analysis. The cost merit is verified based on the efficiency calculation result.

As described above, a process that can automate a common assembly process of a plurality of products is separated into a process that is difficult to automate, and a process that is difficult to automate (a semi-automated process) is prepared and prepared in advance in a manual. This makes it possible to realize an assembly process corresponding to various types.

[0020]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram of a method for manufacturing a plurality of products according to the present invention; FIG. 1 is a process diagram showing an assembly process of the manufacturing method according to the present invention. FIG. 2 is a flowchart showing a construction procedure for constructing an optimal system for producing a plurality of types of products. In this case, as shown in FIG. 1, an assembly process for manufacturing a lithium ion battery will be described as an example. The same components as those in the prior art will be described with the same reference numerals.

The assembly process line of the lithium ion battery is as follows:
As shown in FIG. 2, it is configured according to an optimal production system construction procedure, and includes a manual assembly process 17, a seam welding process 1
4, an EL injection step 15 and an injection hole sealing step 16. Among them, the process indicated by the manual assembly process 17 is a process that is changed as needed by changing the product type.

A lid welding step 14 having a lid welding machine 14A, an EL injection step 15 having an EL injector 15A, and an inlet sealing step 1 having an inlet sealing machine 16A are the subsequent steps.
6 and the like can be commonly used for changing the product type, and these are connected to each other by conveyors 18A, 18B, 18C and the like. Therefore, these steps are performed in an automated step 19.
Function as

Here, the manual assembly process 17, which is changed as needed by changing the product type and contributes to the efficiency, will be described in detail below. Here, an example in which the same system of the cell production system Y and the cell production system Z is configured in the manual assembly process 17 is shown. Therefore, the case of the cell production system Y will be described as an example.

The cell production system Y can be reorganized in accordance with an optimal production system construction procedure described later, and includes a combination of processes in which a semi-automated part and a manual work part are mixed. Has become. This step includes an elastic body supply step 10A, an element insertion step 11A, a negative electrode lead welding step 21, a lead welding step 12
A, a lid temporary fixing step 13A, which functions as a semi-automated step 20.

Each step 10 constituting the semi-automated step 20
A, 11A, 21, 12A, and 13A are each mounted on a trolley, that is, a movable gantry, and can be separated from each other, and semi-automatic machines (jigs A to E) mounted on the trolley in response to a change in the type. The layout can be easily changed by exchanging. Then, delivery is performed manually between these steps. Hereinafter, the work content in each step will be described.

In the elastic body supplying step 10A, the element 30 is taken out from the element tray, and the element 30 taken out is taken out.
Pick and crush. The elastic body 31 is positioned on the crushed element 30 and is attached with a stopper tape 32. The standard time spent in this step is approximately 5.04 seconds.

In the operation of the element injection step 11A, the can 34 is taken out, the element 30 to which the elastic body 31 is attached is aligned with the opening of the can 34, and the upper part of the element 30 is put on the element 30 by hand.
Press 0. The standard time spent in this process is approximately 3.06
Seconds. The work in the negative electrode lead welding process 21 is performed by the element 3
The negative electrode lead coming from 0 is welded by a welding machine corresponding to the jig E.

In the work in the lead welding step 12A, the sealing case 35 is taken out, the electrode portion of the element 30 is positioned, and is fitted into the can 34. The standard time required for this operation is approximately 2.16 seconds. Next, the lid 36 is taken out and set on the jig c. Then, the lead of the element 30 is positioned on the positive electrode of the lid 36 and welded. The standard time spent on these tasks is approximately 3.6 seconds.

The work in the lid temporary fixing step 13A is performed by the element 30
The cover 36 is fitted into the can 34 while bending the lead.
Then, the can 34 is set on the jig D (can insertion machine) and temporarily pressed by hand pressing. The standard time spent in this operation is approximately 3.60 seconds.

The product assembled in this way is taken out of the lid temporary fixing step 13A, put on the conveyor 18A, and is subjected to the following automated steps of lid welding step 14, EL injection step 15, injection port sealing step 16 Sent to and assembled.

In the lid welding step 14, the periphery of the can 34 and the sealing case 35 are sealed by lid welding. In the EL injection step 15, the electrolyte EL is injected into the can 34 from the injection port of the sealing case 35. Can 34 filled with electrolyte EL
Is performed to wipe off the electrolytic solution EL attached to the side surface. The standard time spent in this operation is approximately 1.8 seconds.

In the pouring and sealing step 16, the can 34 is set on a stainless steel ball feeder. Then, the ball 37 is loaded into the injection port using a jig and welded. The standard time spent in this operation is approximately 2.52 seconds. The parts generated in this way are cleaned by checking the welding state of the can 34 (not shown). The standard time spent in this work is approximately 2.
52 seconds.

Next, in order to dry the washed can 34,
The surface of the can 34 is wiped off, water is blown off by air, and the dry state is checked in a hot air drying oven, and the dried state is checked. The standard time spent in this operation is approximately 7.92 seconds.

Next, the dried can 34 is subjected to an X-ray inspection (not shown), the can 34 is set in a soft X-ray apparatus, and the state is checked by a monitor. The standard time spent in this operation is approximately 2.16 seconds.

Next, a pass / fail judgment is made. If the result is acceptable, the sample is taken out of the soft X-ray apparatus, set on a stamping machine and stamped. The standard time spent in this operation is approximately 1.80 seconds. The stamped can 34 is taken out of the stamping machine, put into a battery tray, and carried out. The standard time spent in this operation is approximately 2.52 seconds. Thus, a series of assembly of the lithium ion battery is completed via the semi-automatic process 20 and the automation process 19.

The lithium ion battery is assembled through the above-described steps. Among these steps, the optimum procedure for constructing a production system in the manual assembly step 17 in which the steps are different depending on a plurality of types of products is shown in FIG. As shown in the figure, the procedure is composed of three procedures: a semi-automated analysis procedure A, a personnel effective utilization procedure B, and a cost merit procedure C.

The semi-automated analysis procedure A includes steps ST1 to ST6, and the effective personnel utilization procedure B includes step S1.
From T7 to step ST9, the cost merit making procedure C is configured from step ST10.

First, the operation of each step in the manual assembly step 17
The functions are examined and classified (step ST1). As shown in FIG. 3, this classification is based on the easiness of automation, tooling time, and possibility of manual work in each process.
This is done by classification. Then, in order to perform these three classifications, an operation of specifying an automation target component in each process, a target manual operation, and a target manual inspection is performed.

Specifically, in the elastic body supplying step 10A and the element inserting step 11A of the manual assembling step 17, since the tape attaching operation and the canning operation can be performed by substantially the same operation, automation is possible. In addition, the operations of supplying the elastic body, supplying the electrode elements, and supplying the cans are classified as manual operations because the operations involve a plurality of operations and are difficult to automate.

Further, in these steps, the presence or absence of the elastic body is subjected to a manual inspection instead of an automatic inspection. With this level of inspection, a manual inspection is sufficient since an amateur can easily see the image without introducing an automatic inspection machine.

In the lead welding step 12, since the welding operation is welding to a predetermined location, the operation can be automated, and the work setting operation itself requires a plurality of operations. Classified as manual work.
In the lid temporary fixing step 13, the welding operation is a single operation and therefore can be automated, and the work setting operation and the bending operation include a plurality of operations, and thus are classified as manual operations.

Subsequent lid welding step 14, EL injection step 1
5. The injection port sealing step 16 and the cleaning step (not shown) can be integrated into a single operation, so that automation is possible.

Next, the possibility of semi-automation among those classified as manual work is determined. The operation / function classification in step ST1 shows that the parts supply (parts feeder) part takes a very long time to replace and adjust parts during tooling, and the parts to be subjected to manual operations are often stopped for a short time. Many occur. It is determined whether or not these tasks can be easily automated even if classified into these manual tasks, and tasks that are difficult to automate are transferred to step ST4 and identified as manual tasks (step ST3).

Among the manual work objects, those which are determined to be works that can be easily automated are examined for tooling time (step ST5). The work for which the tooling time is determined to be long is specified as a manual work even if automation is easy (step ST4). Operations determined to have a short tooling time are classified as automation target operations (step ST6).

Next, a procedure B for effectively utilizing personnel is examined, and a work analysis and a work configuration of the work specified as the manual work in step ST4 are performed (step S4).
T7). For the work specified as the work to be automated in step ST6, a semi-automatic machine is designed for automation (step ST8).

Steps ST7 and ST8 can be regarded as a procedure B for effectively utilizing personnel.
To determine whether the work is efficient and the personnel can be used effectively, a method is used to calculate the standard time of the work and classify the work and calculate a general standard time called the so-called BASIC MOST.

In order to calculate the standard time in the assembly work of the lithium ion battery in the embodiment, the work contents,
It analyzes element work, procedure number (NO), unit work, sequence model, total time of each work, etc.
The work balance can be minimized by constructing the optimal machine system, and the two-handed work can be clarified in the work procedure manual.

For example, the elastic body supplying step 1 of the manual assembling step 17
Regarding the work contents of the element / elastic body taping in 1A, as the element work, supply of the element 30, pressurization of the element 30, supply of the elastic body 31, supply of the stop tape 32, and element work of the element / elastic body taping It is configured.

For these work elements, the operation is described as the operation of the contents of each element work, for example, for the supply of the element 30, such as “remove the element from the element tray”. Further, this work operation is analyzed as a sequence model such as A ₁ B ₀ G ₁ A ₁ ... By a basic most method. Here, symbols such as A represent "hand and torso movements", "place", "positioning", and the like, and the numbers in the suffix represent the degree of weighting due to differences in content.

This operation is performed for one time unit (T
MU) is 0.136 seconds, which is 30 TMU, which is a subtotal of 1.08 seconds. In this way, the total time (standard time) of the work content of the element / elastic body taping is 5.04 seconds.

As described above, when the respective work contents are summed up, in this example, the elastic body supply step 10A in which the assembly is completed
A standard time as an assembly time from the injection port sealing step 16 requires 24.84 seconds, and a cleaning / X-ray inspection step (not shown) requires a standard time of 14.40 seconds. Based on the standard time calculated in this way, it is determined whether the work is efficient and the personnel can be used effectively.

Returning to FIG. 2, the cost merit examination procedure C is examined (steps ST9 and ST1).
0). Here, based on the work analysis / work configuration study result in step ST7 and the result of the semi-automatic machine design in step ST8, a determination is made from the viewpoint of whether these works are efficient (step ST9). . If the work is not efficient, the work is fed back to step ST7 or step ST8 and reconsidered, and only the work determined to be efficient is performed.
The cost merit is verified (step ST1).
0).

The cost merit verification means performs superiority verification with a semi-automatic machine in the items of “depreciation cost of equipment”, “labor cost”, “tooling loss”, and “operating rate”, and “switching” which is a variable factor is performed. Breakpoint verification based on "number of times", "production quantity", etc. is performed. This verification is performed using, for example, a cost simulation diagram shown in FIG. On the horizontal axis, the number of times of switching or a variation factor such as the production quantity is used. In the embodiment, the number of times of switching of the tool per month is shown. The vertical axis is the unit cost (yen) obtained by summing up the equipment depreciation cost, labor cost, tooling loss, occupancy rate, etc. per unit.

As parameters, semi-automated analysis means A
In each of the semi-automated cell lines P1, P2, P3, and P4, which are the semi-automated machines specified by (steps ST2 to ST6), the tact time is 24 seconds, 12 seconds, 6 seconds, and 8 seconds,
Breakpoints are verified when the tact time is 4 seconds on the flexible automation line P5, and when the tact time is 2 seconds on the reconfiguration automation line that has been modified so that the current line can be switched between types.

The break point is a comparison between the flexible automation line P5 and the restructuring automation line P6. In this case, if the number of quality changes per month is substantially three or less, the restructuring automation line P6 is used. Indicates that the unit cost is smaller and superior.

The breakpoints are a semi-automated cell line (8 seconds) P4 and a flexible automated line P5.
In this case, when the number of times of quality switching per month is about 5 or less, the flexible automation line P5 has a smaller unit cost and is superior.

As described above, for example, in the lithium battery assembling process, the layout change can be easily performed by placing the semi-automatic machine in each process on the trolley with respect to the difference in the manual assembling process 17 depending on the battery type.

In the semi-automatic machine, only necessary functions (such as a welding function and an insertion function) are added to the desktop robot so that the machine can be put on a carriage. Automatic transfer conveyor and pick and place (p.
By removing the "ick and place" function and eliminating the switching time required for the conveyor by manual delivery, the efficiency of the production line can be further improved.

[0059]

As described above in detail with the embodiments, according to the first aspect of the present invention, a plurality of semi-automated processes are recombined with each other in accordance with the type of product, and the automated process is performed. To reduce the tooling time such as tooling time, tooling materials, etc. Can be improved.

Further, in the semi-automated process, it is possible to manually cope with a part which is a high cost factor and is difficult to automate, and it is possible to reduce the cost by making the automatic quality inspection manual work. Through this, an optimal investment can be made, and the cost of the apparatus can be reduced.

In addition, the equipment is simplified, the equipment development, installation and start-up lead times can be greatly reduced, and less specialized knowledge is required.
There is a merit that anyone can respond.

[Brief description of the drawings]

FIG. 1 is a process chart showing an assembly process of a manufacturing method according to the present invention.

FIG. 2 is a flowchart illustrating a procedure for constructing an optimal system.

FIG. 3 is an analysis diagram showing a work analysis result of a lithium ion battery.

FIG. 4 is a cost simulation diagram for examining the cost of the work shown in FIG. 1;

FIG. 5 is a configuration diagram showing an assembly line of a lithium ion battery.

[Explanation of symbols]

10A; elastic body supply step, 11A; element insertion step, 12
A: lead welding step, 13A: lid temporary fixing step, 14: lid welding step, 14A: lid welding machine, 15; EL injection step, 1
5A; EL injection machine, 16; injection port sealing step, 16; injection port sealing machine, 17; manual assembly step, 19; automation step, 20;
Semi-automated process, 21; negative electrode lead, 30; element, 31;
Elastic body, 32; stop tape, 34; can, 35; sealing case, 36; lid, 37; sphere, A; semi-automated analysis procedure, B;
Procedure for effective use of personnel, C: Cost merit verification procedure

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3C030 DA04 3C042 RA27 RJ11 5B049 AA06 BB07 CC22 CC23 CC31 5H028 AA01 BB17 BB18

Claims (5)

[Claims] 1. A manufacturing method for manufacturing a plurality of types of products, comprising: an automation step for automatically manufacturing a product; and a plurality of movable semi-automation steps which incorporate a semi-automatic machine and are movable. And a method of manufacturing a plurality of types of products in which the semi-automated processes are recombined with each other in accordance with the type of the products and the products are manufactured in cooperation with the automated processes. 2. The method according to claim 1, wherein the semi-automated process is mounted on a movable base so that a layout can be changed according to a difference in the process depending on the product type. 3. The method according to claim 1, wherein said product is a lithium ion battery. 4. Analyzing the work corresponding to the product type into work suitable for an automatable work or a manual work, designing a semi-automatic machine corresponding to the automatable work, Manual work analysis based on standard time is performed for the work covered by the manual.
A method for constructing a production system, wherein the efficiency of these operations is calculated by using the work by the semi-automatic machine and the result of the manual work analysis, and the cost merit is verified based on the efficiency calculation result. 5. In the manual work, it is determined whether or not automation is easy. If the work is easy, it is determined whether the quality switching time is long. The long work is incorporated in the manual work, and the short work is performed in the manual work. The method according to claim 4, wherein the method is incorporated into the work that can be automated.