JP2003114712A - Centralized storage method for half-finished repair sheet metal parts - Google Patents

Abstract

PROBLEM TO BE SOLVED: To store repair sheet metal parts with reduced cost. SOLUTION: Sheet metal parts half-pressed at the pre-coating stage, pressed parts 6, subcomponents 7, or the like, are placed one upon another as half- finished parts, wrapped in a rust preventing sheet 12 into a storage-oriented package 10 which is stored as a unit package. Such centralized storage is implemented when a prescribed number is reached out of the number expected to be demanded, for instance, when the total volume of metal molds coincides with the total volume of half-finished parts in storage. At this time point, the total amount of the half-finished parts expected to be demanded are packaged en-bloc for storage, and the metal molds are discarded. The half-finished parts in storage will undergo additional treatment as demanded and will be issued as finished parts when required.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an advantageous collective centralized storage method for stock sheet metal parts, such as repair sheet metal parts for automobiles, which are obliged to be stored for a long period of time.

[0002]

2. Description of the Related Art When stocking semi-finished products for daily production, the number of storage days is at most a few days, so there is no difficulty in storage and inventory management (such short-term semi-finished product inventory management As an example of
No. 50). However, the situation is different when the repair part has a predetermined storage period and is a relatively large sheet metal part.

The upper part A of FIG. 1 shows a conventional storage method for a rear panel corresponding to a rear outer plate of an automobile as an example of this kind of repair sheet metal part, and predetermined processing such as pressing and coating are completed. Each of the finished rear floor panels of the finished product is packed in a package 1 for sale and stored in a rack 2 one by one. The vertical (Y), horizontal (X), and height (H) dimensions of the finished package 1 for sale are relatively large. This repair sheet metal part is
The inventory is adjusted according to a predetermined demand forecast, and it is obliged to store and supply the automobile for a predetermined period after the manufacture of the main body of the vehicle is finished.

The upper part of FIG. 2 shows the steps from the manufacture to the storage of sheet metal parts in this conventional example. First, the original sheet 3
Is prepared (step (1)), and this is drawn into a predetermined shape to form a draw-molded product 4 (step (2)). Further, trimmed product 5 is formed by trimming unnecessary parts ( Process
(3)), and then bend it or bend or pierce it to make a hole at a predetermined place to obtain a press finished product 6 (step
(Four)). The pressing step is completed through these steps (1) to (4). The pre-press process (2) (3) and post-press process
The unpressed product in (4) is an in-press product, and when the pressing process is completed through these processes (1) to (4), it becomes a pressed product. Further, sub-comp 7 is formed by assembling and integrating component parts consisting of small parts such as nuts with the press-finished product to form sub-comp product 7 (process (5)), and then painting is completed. Product 8 (Process
(6)), and packing them one by one to form the finished product packing form 1 (process (7)), and the process ends. The sheet metal parts are produced in small lots according to the stock situation, and the stock is adjusted.

[0005]

By the way, in the above-described conventional example, since the finished product 1 is stored, a large storage space is required, and the storage cost increases. In particular, sheet metal parts for automobiles such as a vehicle body outer panel tend to be large in size, which further increases the storage cost. In addition, since small lots are produced and stored many times according to the stock situation, the manufacturing cost increases.

Furthermore, in order to supply for a long period of time by such intermittent production, it is necessary to keep the mold for the entire period, which causes mold storage costs, rust prevention costs, maintenance costs, etc. This also increases the cost of inventory storage. In addition, if the sheet metal parts are large, the large-scale factory that can own the large molds for manufacturing the sheet-metal parts will be limited, so the manufacturing location will be limited, and small lots will be manufactured in relatively small factories. It is difficult to take such agile response. In addition, storing the finished product after painting may result in defective products due to paint scratches during storage, or it may be difficult to flexibly respond to differences in the number of demands for each color. Also, it is difficult to flexibly deal with derivative types with different fine parts such as adding child parts and holes.
Therefore, an object of the present invention is to provide an efficient inventory storage method for such repair sheet metal parts.

[0007]

SUMMARY OF THE INVENTION In order to solve the above problems, the invention relating to a method for centralized batch storage of repair sheet metal parts according to the present invention includes a pressing step such as drawing, trimming, bending and piercing and welding from a plate member. In the collective centralized storage method, where the semi-finished sheet metal parts manufactured through each process of assembly and painting are collectively stored as a repair inventory, when the expected demand number falls below a predetermined set value, at least the sheet metal parts before painting are It is characterized in that a plurality of semi-finished products are collectively covered with a rust preventive sheet to be stored as one package and the mold is discarded.

At this time, the predetermined set value in the expected demand number is set when the package volume of the semi-finished products to be stored together and the volume of the mold and the storage amount of the package parts and the storage amount of the mold match. It can be a value. Further, the stored semi-finished product is subjected to additional processing according to demand and shipped as a finished product.

Further, the stocked semi-finished product is a half-pressed product that is trimmed, drawn, bent, or pierced during the press process, which is in the middle of the press process, a press-finished product, or this press-finished product. On the other hand, any of the sub-comp products in which other components are integrated may be used. In addition, the composition of the sub-comp product is such that the press finished product and other parts are assembled and integrated by welding etc., or the press completed product or semi-finished product and other parts are combined and integrated so that they can be stored together (hereinafter, This can be either a tie. Further, by receiving an order for the repair parts of the finished product, it is possible to assemble and supply the semi-finished products collectively centrally stored.

[0010]

According to the present invention, when the expected demand number reaches a predetermined set value, the repair sheet metal parts are collectively manufactured as semi-finished products, and a plurality of these are packaged and stored as one unit. Therefore, the storage space can be significantly reduced. Further, since the molds are discarded at the same time, the molds are released from long-term storage, and the cost increase due to this is avoided.

The semi-finished products stored in a batch are then subjected to additional processing according to demand to be finished products and supplied in required quantities. At this time, since the semi-finished product is at least unpainted, it can be painted in an indispensable color according to demand, and it is possible to flexibly cope with the difference in the number of demands depending on the color. In addition, the paint during storage does not get scratched. Moreover, the stock whose storage period has expired can be discarded in the state of semi-finished products, and the process up to the completion of the finished products is omitted, so the costs associated with disposal can be saved.

Further, if the predetermined set value in the expected demand number is set to a value when the package volume of the semi-finished products to be stored in batch and the volume of the mold coincide with each other, the semi-finished products are thereafter set to a predetermined length. Even if it is stored for a certain period of time, by discarding the mold, the storage space can be used in time, so that the storage space is minimized, and it is possible to advantageously store the inventory of repair sheet metal parts for a long period of time.

In addition, the semi-finished products to be stocked include intermediate products in the press process such as draw, trim, bend or pierce, which are in the middle of the pressing process, press-finished products and other parts to the press-finished products. It may be any of the sub-comp products assembled and integrated in. The storage space can be minimized because the volume of each intermediate product such as trimmed products is the smallest. In the case of a press-finished product, the volume is larger than that in the middle of the pressing process, but since the process that requires a large-sized press machine is completed, the processing place is not limited thereafter, and flexible processing is possible. Furthermore, in the case of a sub comp product, the volume is the largest, but since it is integrated by other welding or tie storage, it is not necessary to stock these assembled parts (including the mold in some cases) separately, and parts management It is advantageous in terms of inventory storage.

In addition, the semi-finished products stored in a batch can be subjected to additional processing according to demand to obtain finished products, which can be supplied in required quantities. At this time, since the semi-finished product is at least unpainted, it can be painted in an indispensable color according to demand, and it is possible to flexibly cope with the difference in the number of demands depending on the color. In addition, it is possible to flexibly deal with derivative types with different minute parts such as adding child parts and adding holes, as well as colors. Moreover, the finished product can be obtained only by additionally processing the semi-finished product, so that the lead time from order receipt to supply can be shortened. In addition, since additional processing for semi-finished products is relatively simple, restrictions on the equipment owned by the subcontractor when subcontracting the additional processing are lessened, and the degree of freedom in selecting subcontractors is increased.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION A storage method using a vehicle rear panel as a repair sheet metal part will be described below with reference to the drawings.
As shown in the lower part of FIG.
Trimmed product 5 which is a processed panel at the stage (3))
Are stacked to form one package (step (8)), or the press-finished product 6 or the sub-compressed product 7 is similarly packaged (step (9)). In this case, the trimmed product 5 has a smaller dimension in the height direction than the press completed product 6 since it is before the bending and piercing in the latter stage of the pressing, and has a height of, for example, 1/20. Therefore, if the packing height is the same, the largest number of sheets can be packed into one packing. However, in-press products at various stages and press-finished products have the above-mentioned storage advantages, although they differ to some extent from the sub-comp products.

Further, as in the step (9), the subcomp product 7
By packaging, the other components such as child parts can be integrally stored by welding or tie storage, so that it is not necessary to separately store these other components, which is advantageous for storage when the number of component parts is large. At this time, vertical (y) and horizontal (x)
The respective dimensions are similar to XY in the finished product packing 1. The semi-finished products stacked by these steps (8) or (9) are made into a collective storage package 10 for one-time storage which is packed in one step (10). The dimensions are XYH in the finished product packaging 1.
May be almost the same as. It is also possible to collectively store the pressed products in a batch.

As shown in the lower part of FIG. 1, the collective package 10 for collective storage is stored in the rack 2 one package at a time.
Even if the rack 2 as a whole has the same size, the storage amount of the conventional example in the upper stage is remarkably increased as compared with the case where the finished products are packed one by one. .
That is, even if the collective package 10 for collective storage is substantially the same as the dimension XYH of the finished product package 1, the internal capacity is significantly increased.

FIG. 3 shows an example of packing when the pressed finished products 6 are stored in a lump, and the pressed finished products 6 are piled up in units of 5 to 50 and the corners are made of a known appropriate cushioning material such as foam material. Apply the anti-corrosion tool 11 and seal the whole with a rust preventive sheet 12 made of an appropriate material such as vinyl having excellent rust preventive property, and surround the circumference with a frame 13 of wire rods to collect a package in a package for collective storage 10 And This collective storage package 10 for batch storage is a unit of a transport mode that can be loaded and unloaded by a forklift or the like, and the frame 13 is provided with a strength to withstand such transport.

The packaging with the rust preventive sheet 12 is required to exhibit a predetermined rust preventive property so that the semi-finished product which is the content does not rust over a long period of time. FIG. 4 exemplifies this rust preventive test method, which is determined by a constant temperature and humidity tank test according to a predetermined summer / winter one day cycle. In this test, the summer-winter day cycle is set to a predetermined number of times, for example, 10 cycles / year, and if this is repeated for 5 to 10 years of the storage target number of years and no rust is generated, it is judged as passing.

In the day of summer and day constituting the summer-winter day cycle, the temperature is 65 ° C., the humidity is 85% for 3 hours, the temperature is 25 ° C. and the humidity is 40% for 3 hours, and then the temperature is lowered to 0 ° C. In the winter 1-day cycle, the temperature is kept at 0 ° C. for 3 hours, then the temperature is kept at 25 ° C. and the humidity is 40% for 3 hours, and the temperature is further raised to 65 ° C. and the humidity is 85%. The time until the first day of the summer day is started is set as the overall start-up time (for example, 1 hour).

FIG. 5 is a diagram for showing the timing setting of this batch storage, and the curve is a demand curve showing the demanded number of repair sheet metal parts expected to be required in a certain period (year, month, etc.). is there. The horizontal axis is the period and the vertical axis is the forecast demand quantity and volume of the repair sheet metal parts. The demand curve rises after the car is released and reaches peak C in a predetermined period,
After that, it begins to decline gently. This demand curve is determined based on empirical rules. Of the demand curves, the solid line shows medium demand and the broken line shows small demand.

The demand curve intersects with the reference storage amount line D at a point E after a certain period of time passing through the peak C. In the period up to this point E, if there is a medium or higher demand as indicated by the solid line, the mold is held and the product is supplied by lot production. Items that are entirely below the standard storage amount line D as indicated by the broken line are collectively stored as described later.

The standard storage amount line D is set as a line in which the volume of the collective inventory storage amount at the point E coincides with the volume of the mold, and corresponds to a predetermined set value in the present invention. In addition, the bulk inventory storage amount is on the demand curve at point E.
After that, it is the amount integrated until the inventory deadline.

When the solid demand curve intersects with the standard storage amount lines D and E, the expected total amount to be stored thereafter is manufactured in the state of the semi-finished product, and then the mold is discarded. Move to storage and then store for a specified period. Point G is the supply period of parts, and there is no special meaning at this point in the die storage in this embodiment, but conventionally it is necessary to continue to hold the die until the predetermined supply period from this point. It was

Incidentally, as shown by the broken line, in the case of a product having a demand curve with a small demand, a considerably early period,
For example, when it coincides with the reference storage amount line D at the time of peak F, the batch storage is started at this time F, and the latter half finished product is stored for a predetermined period.

Next, the operation of this embodiment will be described. When the expected demand quantity reaches the predetermined set value D as described above, repair sheet metal parts are manufactured as a semi-finished product (5, 6 or 7) in a batch, and a plurality of these are made into one unit to be a collective storage assembly. Package 10
Pack and store in. Therefore, the storage space can be significantly reduced. Further, since the molds are discarded at the same time, the molds are released from long-term storage, and the cost increase due to this is avoided.

The semi-finished products (5, 6 or 7) stored in a batch are then subjected to additional processing according to demand to obtain finished products, which are supplied in required quantities. At this time, since the semi-finished product (5, 6 or 7) is not yet painted, it can be painted in an indispensable color according to demand, and it is possible to flexibly deal with the difference in the number of demands depending on the color. In addition, the paint during storage does not get scratched.

Furthermore, the stock whose storage period has expired can be discarded in the state of semi-finished products, and the process of making it into a finished product is omitted, so that the costs associated with the disposal can be saved.

Further, the predetermined set value D in the expected number of demands is a value when the packing volume of the semi-finished products (5, 6 or 7) to be collectively stored and the volume of the mold match. Therefore, even if the semi-finished product (5, 6 or 7) is stored for a predetermined long period of time thereafter, the storage space will be the shortest because the mold is discarded and the storage space will be sufficient for a long period of time. Inventory storage of repair sheet metal parts can be made advantageous.

In addition, the semi-finished product to be stocked may be any of the in-press product in the middle of the pressing process, the pressed product 6 or the sub-comp product 7 in which other parts are assembled and integrated with the pressed product by welding or the like. Good. The in-press product may be any of the trimmed product 5, various stages such as draw, bend, and piercing as long as it is in the incomplete press state. For example, in the case of the trimmed product 5, the volume per piece The storage space can be minimized because the size is minimized.

The finished press product 6 has a larger volume than the trimmed product 5, but since the process that requires a large press machine is completed, the working place is not limited thereafter, and flexible working is possible. become. In addition, the size of the press machine changes before and after trimming even in the middle of pressing, so a smaller general-purpose machine can be used for the bend and piercing after trimming. In the case of the sub-comp product 7, the volume is the largest, but since other assembly parts are also integrated, it is not necessary to stock these assembly parts (including their molds in some cases) separately, and parts management and inventory It has an advantage in storage.

FIG. 6 is a cost comparison between the storage methods of steps (8) and (9). First of all, when storing the trimmed product 5,
By packing 0 sheets into one package, when the total cost a and the cost per piece b are set, the total cost c is slightly higher than the total cost c when packing 10 sub-complement products 7 each. However, the cost e per piece is much larger than the cost b. Therefore, in terms of cost, the subcomp product 7
It is more advantageous to store the trimmed product 5 than the trimmed product 5. The same applies to the case where the press completed product 6 is used instead of the subcomp product 7.

[Brief description of drawings]

FIG. 1 is a diagram showing a package shape of a repair sheet metal part during storage together with a conventional example.

FIG. 2 is a view showing a manufacturing process and a packaging process together with a conventional example.

[Figure 3] Diagram showing the packing method

FIG. 4 is a diagram showing a rust prevention test method.

FIG. 5 is a diagram showing the timing of determining the set demand quantity.

[Figure 6] Cost comparison chart based on packaging

[Explanation of symbols]

1: Packaging of finished products for sale 2: Rack, 3: Original sheet, 4: Draw molded product, 5: Trimmed product, 6: Pressed product, 7: Subcomp product, 8: Completed product, 10: Batch Collective package for storage, 11: Tear-prevention tool, 12: Anticorrosion sheet, 13: Frame

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Masahiro Noshiro             2-1-1 Minamiaoyama, Minato-ku, Tokyo Honda Gi             Ken Kogyo Co., Ltd. F term (reference) 3C100 AA45 BB05 EE01

Claims (7)

[Claims] 1. A method of storing sheet metal parts manufactured from a plate-shaped member through press steps such as draw, trim, bend and piercing, and welding, assembling and painting steps as a stock for repair, and an expected number of demands. When the value falls below a predetermined set value, at least the sheet metal parts in a semi-finished product state before painting are collectively covered with a rust preventive sheet and stored as one package, and the mold is discarded. A method for centralized storage of semi-finished sheet metal parts for repair. 2. The predetermined set value for the expected number of demands is a value when the packaging volume of the semi-finished products to be collectively stored, the volume of the mold, and the packaging component storage amount and the die storage amount match. The method for collectively storing semi-finished products of repair sheet metal parts according to claim 1, wherein 3. The half of the repaired sheet metal part according to claim 1, wherein the stored semi-finished products are shipped in a required quantity as finished products by performing additional processing according to demand. Centralized storage method for finished products. 4. The semi-finished product is a press-finished product that has been subjected to a draw, trim, bend, piercing, or the like, which is in the middle of a pressing process, and is in the middle of a press process. Centralized storage method for semi-finished products of repaired sheet metal parts. 5. The method for collectively storing semifinished products of repair sheet metal parts according to claim 1, wherein the semifinished product is a press finished product. 6. The semi-finished product of a repair sheet metal part according to claim 1, wherein the semi-finished product is a sub-comp product obtained by welding other parts to a press-finished product. Collective centralized storage method. 7. The semi-finished product of the repair sheet metal part according to claim 1, wherein upon receipt of an order for the finished product repair part, the semi-finished product collectively stored in a batch is assembled and supplied as a finished product. Collective centralized storage method.