JP2003118841A - Method for controlling part stock, instruction method for delivery to part dolly, and system for controlling stock - Google Patents

Abstract

PROBLEM TO BE SOLVED: To grasp parts stock more accurately for each process. SOLUTION: A production instruction computer 23 acquires product-specifying bar codes from a bar code reader 22 installed at a finished product inspection stage on a production line 21 and, based on the codes, develops information of part level indicating the types and quantities of parts. The computer 23 calculates the quantity of each type of parts used for the quantity of manufactured products. The quantities of parts in stock at each process are calculated by using the quantities of parts used and the quantities of parts transferred to the respective processes by the parts dolly 26.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a process inventory management method, a delivery instruction method to a parts carrier, and a process inventory management system.

[0002]

2. Description of the Related Art In a factory production line, it is not possible to place all the parts required for daily production near the line. Therefore, when parts are reduced to a certain extent, parts should be delivered to each process of the line. It has become.

In order to deliver the parts to the production line, it is necessary to grasp which process is running out of which parts.
Therefore, conventionally, a "kanban" corresponding to a part for each process, or a box containing parts was used as an "empty box kanban", and parts were delivered to each process based on those kanbans. A kanban is made of paper, plastic, or the like, and describes the part number, product name, required quantity, required process, manufacturer, and the like. Similarly, the empty box kanban is also indicated with the product number, product name, number of products, and the like.

FIG. 7 is an explanatory view of a conventional Kanban type parts delivery method. The in-process kanban 11 or empty box kanban 12 (hereinafter collectively referred to as kanban 11) provided for each process is collected in a collection post (not shown) in the line, and further, the kanban collection / delivery room from the collection post. Collected in 13.

Computer 14 in Kanban collection and delivery room 13
Receives a production instruction (type of product to be produced, production quantity, production order, etc.) from the host computer 15 of the upper level. Further, the operator confirms the contents of the collected kanban 11 and inputs the parts that need to be delivered to the computer 14. Then, based on the production instruction from the host computer 15 and the parts designated by the kanban 11, the computer 14 instructs the warehouse to deliver the parts.

When a part is unloaded from the warehouse, the on-site truck transports the part to the parts storage area 16. Then, the parts carrier 17 delivers the parts to the rack of the process corresponding to the line.

[0007]

In the above-described conventional method for delivering parts using the kanban 11, the kanban 11 is collected in the kanban collection / delivery room 13 and only the quantity of parts corresponding to the kanban 11 is known. However, it was not possible to accurately grasp the inventory of parts in the process.

[0008] Further, the Kanban 11 collected from the process of the line stays in the collection post and the Kanban collection and delivery chamber 13, and the Kanban 11 is used for the instruction to pick up the parts and to issue the warehouse. Since it takes a long time to move the kanban 11 to a desired place and it takes time from the delivery request of parts to the actual delivery of parts to each process, each process must have an extra inventory of parts. There was also the problem that it had to be done.

As a method of checking the inventory of parts in the process,
It is conceivable that the worker will check the inventory of each process, but this method is labor intensive and not an efficient method. As another method, it is conceivable to install a bar code reader in each process and read the bar code recorded on the part to grasp the number of parts used in the process.

However, this method requires the operator to read the bar code and also aligns the parts placed in the parts box in different directions so that the bar code can be read. However, there arises a problem that the burden on the operator increases.

As a known technique of the manufacturing control method, for example,
JP-A-8-12026 is known. This publication describes a method of carrying materials, manufacturing instructions, and inventory management in a factory that manufactures steel sheets with a small number of people or unattended. However, according to the present invention, the order of each steel manufacturing process flow is arranged according to the order information so that a production plan for the entire manufacturing process can be established.
It is only one of the characteristics, and also relates to the manufacturing process of one part called steel strip.

An object of the present invention is to make it possible to more accurately grasp the inventory of parts in a process. Other challenges are
It is to grasp the inventory of each process and to be able to instruct a parts carrier about the parts to be delivered to each process.

[0013]

According to an inventory management method of each step of the present invention, based on information about a product produced in a production line, it is developed into information on a level of parts constituting the product, and a production quantity of the product is produced. And calculate the usage quantity of each part used in the product based on the part level information,
The inventory quantity of parts in each process is calculated based on the used quantity and the information about the parts delivered to each process.

According to the present invention, it is possible to accurately grasp the inventory of parts in each process. As a result, the necessary number of parts can be delivered to each process when it is necessary so as not to run out of parts. Therefore, it is not necessary to have an inventory of parts more than necessary in each process, so that the stock quantity of parts can be reduced. Further, since the kanban is not used, not only the work of creating the kanban becomes unnecessary, but also delay of delivery of parts due to time-consuming collection of kanban, and lack of parts due to loss of kanban do not occur.

The method of instructing delivery of a parts carrier of the present invention expands to the information of the parts level constituting the product based on the information on the products produced in the production line, and the production quantity of the products and the parts level Based on the information, the usage quantity of each part used in the product is calculated, and based on the usage quantity and the information about the parts delivered to each process, the stock quantity of the parts of each process is calculated, and the stock quantity is calculated. The quantity of the parts to be delivered to each process is calculated based on the above, and the information about the parts to be delivered and the information indicating the process of the delivery destination of the parts are displayed on the display device of the parts carrier.

According to the present invention, since the stock quantity of parts in each process can be grasped in real time, it is possible to instruct the parts carrier to deliver the parts so that the parts are not out of stock in each process. it can. Further, information on the process of the delivery destination and the parts to be delivered (for example, the part name and quantity) is displayed on the display device of the parts carrier, and the driver of the parts carrier looks at the display and displays the parts for each process. Since delivery can be performed, the efficiency of delivery work can be improved.

In the inventory management method of the above invention, the information indicating whether or not the parts carrier has stopped in the process of the destination for delivering the parts is acquired, and the information is the destination of the parts carrier. If it indicates that the process is stopped, the inventory quantity of the parts of the process is calculated based on the calculated use quantity of each part and the information on the parts delivered to the process of the delivery destination, and If the information indicates that the parts carrier did not stop at the delivery destination process, the stock quantity of the parts in the process may be calculated based on the calculated usage quantity of each part. good.

With this configuration, for example, it is possible to judge whether or not the parts are replenished in the process by acquiring information indicating the process stopped by the parts carrier for unloading the parts or the position thereof. can do. Therefore,
It is possible to more accurately grasp the inventory of parts in each process based on the result of the determination.

In the above invention, the information for specifying the product and the information for specifying the parts used in the product are stored in association with each other, and when the information for specifying the product is acquired, the information is associated with the information. You may make it expand | deploy to the said information of the said component level by acquiring the information which identifies the component currently used for the said product.

With this configuration, it is possible to obtain information specifying the parts used in the product from the information specifying the product. The inventory management method of the process of the present invention is based on the information for identifying the product and the information on the rejected product determined to be rejected in the inspection process, and the parts used for the finished product and the rejected product and the parts. And the quantity of each of the parts used in the finished product and the product based on the quantity of the finished product and the rejected product and the quantity of the parts used in the finished product and the rejected product. Is calculated, and the inventory quantity of the parts in each step is calculated based on the used quantity of each part and the information about the parts delivered to each step.

According to the present invention, it is possible to obtain the parts used in the finished product and the inspection-failed product and the quantity of the parts. Therefore, the inventory quantity of the parts in each process can be more accurately obtained from the information. You can figure it out.

In the above invention, the information on the parts delivered to each of the processes includes the information designating the parts and the quantity of the parts.

[0023]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is an explanatory diagram of an inventory management method of a process according to the first embodiment of this invention.

A bar code reader 22 is installed in the process of inspecting the finished product on the production line 21. A bar code for identifying the product is printed on a label or the like and attached to each product, and the bar code reader 22 reads the bar code of the product. The barcode read by the barcode reader 22 is transmitted to the production instruction computer 23 as information for specifying the product specifications.

When the production instruction computer 23 acquires the barcode of the finished product from the barcode reader 22, the production instruction computer 23 develops the barcode into information on the part level. For example,
The production instruction computer 23 stores a plurality of barcodes for identifying products and data indicating the configuration of parts used in each product in association with each other in a storage device such as a hard disk, and corresponds to the obtained barcodes. The data indicating the component configuration of the product to be processed is read out from the storage device and developed into component level information. Further, the production instruction computer 23 identifies the product by the bar code output from the bar code reader 22, and develops the product into parts level information indicating the parts used in the product and the usage quantity of each part. Further, the production quantity is counted by a counter provided on the production line or a bar code output from the bar code reader 22.

The production instruction computer 32 calculates a cumulative total of the used quantities of the respective parts used in the product from the used quantity of the parts used in one product and the production quantity, and the total used quantity and the host computer. Based on the production instruction from 15 (type of product to be produced, production quantity, production sequence, etc.), the stock management computer 25 is instructed to deliver the component from the component storage area 24.

The production instruction computer 23 gives an instruction for transporting parts to each process to the parts carrier 26, and
The contents of the instruction to deliver the component to each process instructed to the component carrier 26 are stored.

Further, the production instruction computer 23 calculates the stock quantity of the parts in each process based on the used quantity of parts corresponding to the production quantity of the product and the quantity of each part delivered by the parts carrier 26 to each step. To do. The parts used in each process are known in advance.

FIG. 2 is an explanatory diagram of wireless communication of the component carrier 26. A wireless repeater 32 is installed on the ceiling of the factory and relays a wireless signal transmitted from the component carrier 26 and transmits it to the antenna 33 of the house 31. This antenna 33 is connected to the production instruction computer 23, and the production instruction data from the production instruction computer 23 is transmitted from the antenna 33, which has been converted into a radio signal, to each component carrier vehicle 26 via the relay 32. . Further, the wireless signal transmitted from the component carrier 26 is relayed by the relay 32 and received by the antenna 33. Further, wireless signals can be transmitted and received between the component carriers 26.

Upon receiving the delivery instruction from the production instruction computer 23 by radio, the parts carrier 26 displays the delivery instruction content on the display device. The driver sees the delivery instruction content displayed on the display device of the component carrier 26 and delivers the component to the corresponding process.

The parts carrier 26 has a position detecting function. When the parts are delivered to the instructed process, it detects which process of the production line 21 is stopped, and the detected position is wirelessly detected. It is transmitted to the production instruction computer 23.

FIG. 3 is a diagram showing a position where the component carrier 26 is stopped for unloading. The process indicated by a black circle in FIG. 3 is a process stopped to replenish parts, and the component carrier 26 wirelessly transmits the position information or information indicating the process to the production instruction computer 23.

Now, the processing of the production instruction computer 23 of the inventory management system of the first embodiment will be described with reference to the flowchart of FIG. The operation of the computer other than the production instruction computer 23 is also described in the flowchart of FIG.

The barcode of the finished product is read by the barcode reader 22 (FIG. 4, S11). The production instruction computer 23 receives the bar code read by the bar code reader 22 and develops it into component level information based on the bar code (S12). In this process, it is possible to identify from the bar code of the product which part was used at what time, and further accumulate the quantity of the parts used in one product for the number of production units to use the quantity of each part. The cumulative value of (hereinafter, simply referred to as the used quantity) is calculated.

Further, the production instruction computer 23 is based on the production plan, the quantity of parts used in the production line, the process of delivering the parts to the parts carrier 26, the kind of parts to be delivered, and the quantity of parts used. The parts carrier 26 is wirelessly instructed which parts, how many parts, and at what time they should be delivered (S13). The delivery instruction for this part is 26
Is displayed on the display device, the driver loads the parts in accordance with the displayed delivery instruction and delivers the parts to the designated process.

Next, it is determined whether or not the component carrier 26 has stopped at the process instructing the delivery of the component (S12). Information indicating in which process the parts carrier 26 has stopped is transmitted from the parts carrier 26 to the production instruction computer 23.

When the parts carrier 26 stops at the designated process (S14, YES), the process proceeds to step S15 to check and record which parts, how many, and when the parts were delivered to the target process for which delivery was instructed. To do. Then, from the usage quantity of the parts used in the produced product and the quantity of the parts actually delivered to each process, it is calculated which parts and which parts are currently in stock in each process (S16). ).

When the parts carrier 26 is not stopped in the instructed process (S14, NO), the process proceeds to step S17, and it is recorded that the parts are not replenished in the process (. Based on the used quantity of the parts used in the product, it is calculated which parts are currently in stock in each process (S18).

By the above processing, the stock of parts in each process can be grasped in real time. According to the first embodiment, the bar code reader 22 installed on the production line reads the bar code given to the product, and the kind of the part produced and used for all the products and the respective parts are used. You can know the used quantity in real time. Further, it is possible to know the quantity of parts delivered to each process. Therefore, the inventory of parts in each process can be accurately calculated from the used quantity of parts used in production and the quantity of parts delivered to each process. Therefore, the delivery of parts can be instructed at an appropriate timing so that there is no shortage of parts in each process. As a result, it is not necessary to stock extra parts in each process in consideration of delay in delivery of parts, and the stock of parts can be significantly reduced in the entire factory.

Further, the production instruction computer 23 obtains information indicating which process of the production line the component transport vehicle 26 has stopped from the component transport vehicle 26, the information, the quantity of the components delivered to each process, and the production. It is also possible to calculate the inventory quantity of the component in each process based on the used quantity of each component used in the above. In this case, since the quantity of the parts actually delivered to the process can be grasped, the inventory of each process can be grasped more accurately.

In the above-described first embodiment, the bar code is recorded for each product and the bar code is read for each product. However, it is not always necessary to record the bar code for each product. There is no. For example, when multiple types of products with different specifications are produced on one production line, it is possible to obtain information that identifies the product when starting production, or to add a barcode to the first product on the production line. The bar code may be recorded and read, and the production quantity of the product may be counted by a sensor or the like. Even in this case, it is possible to calculate the parts used in the product and the quantity used, from the information specifying the product to be produced and the production quantity, and further calculate the inventory quantity of the parts in each process.

Next, a second embodiment of the present invention will be described, in which the inventory of parts in each process is managed more accurately by reflecting the defect information by inspection. FIG. 5 is an explanatory diagram of the inventory management method of the process of the second embodiment. In the production system of the second embodiment, the bar code reader 41 is provided in each intermediate inspection process in the production line 21, and the bar code reader 22 described above in the finished product inspection process is provided.
Is provided. When a defect is found in the intermediate inspection process or the completion ratio inspection process, the barcode read by the barcode reader 41 or 22 is transmitted to the production instruction computer 23.

The host computer 42 determines the monthly production instruction, the delay or advance of the monthly production instruction, gives a production plan change instruction to the production instruction computer 23, and when it finds a continuous defect from the inspection information, the production instruction is issued. Instruct the computer 23 to analyze the cause.

The production instruction computer 23 calculates the quantity of the parts used in the defective product from the information about the defective product obtained from the intermediate inspection process or the finished product inspection process, and uses it for the finished product obtained from the completed product inspection process. The quantity of parts of the defective product is added to the quantity of parts used to calculate the quantity of parts actually used in the process. Then, the inventory of the parts in each process is obtained from the used quantity of the parts used in the process and the quantity of the parts delivered to each process by the parts carrier 26.

According to the second embodiment, when a defect is found at the stage of intermediate inspection or finished product inspection,
Since the stock quantity of parts in each process can be calculated in consideration of the quantity of parts used in the defective product, the stock in each process can be grasped more accurately.

Next, FIG. 6 is a flow chart showing the processing of the production instruction computer 23 which realizes the inventory management method of the process of the third embodiment of the present invention. In the third embodiment, the stock quantity of each process is calculated in consideration of the number of reusable parts among the parts used in the product in which the defect is detected in the inspection process. .

The bar code reader 22 reads the bar code of the finished product (FIG. 6, S21), and the production instruction computer 23 develops the information at the component level based on the bar code (S22). These processes are the same as the processes of steps S11 and S12 of FIG. 4 described above.

When a defect of the product or parts is detected in the intermediate inspection or the finished product inspection, reusable parts are extracted (S23). Then, the quantity of reusable parts is subtracted from the quantity of parts used in the finished product and the defective product to calculate which part, how many, and by what time (S24).

Further, the production instruction computer 23 issues an instruction to deliver the parts to each process to the parts carrier 26 based on the production plan and the quantity of parts used in the production line (S25). Then, it is determined whether or not the component carrier 26 has stopped at the process instructing the delivery of the component (S26).

When the component carrier 26 stops at the designated process (S26, YES), the process goes to step S27 to record which component, how many, and at which time the component was delivered to the target process for which delivery was instructed. Then, based on the value obtained by subtracting the quantity of reusable parts from the used quantity of parts used for finished products and inspection-failed products and the quantity of parts actually delivered to each process, The inventory quantity of the parts is calculated (S28).

On the other hand, if the parts carrier 26 is not stopped in the instructed process (S26, NO), step S
In step 29, it is recorded that the parts were not replenished in the process (S29). Then, the stock quantity of the parts in the corresponding process is calculated from the value obtained by subtracting the quantity of the reusable parts from the quantity of the parts used in the finished product and the inspection-failed product (30).

According to the third embodiment, the number of reusable parts used in a product that has failed in the intermediate inspection or the finished product inspection is used in the rejected product. By subtracting from the quantity of existing parts, it is possible to obtain the actual quantity used of parts excluding the quantity of reusable parts. Since the quantity of the parts delivered to each process can be calculated from the information of the parts delivered by the parts carrier 26, the stock of the parts of each process can be accurately calculated in real time from those quantities. This allows
Since it is possible to supply the required number of parts when needed for each process, it is not necessary to have an extra part inventory in each process of the production line 21, and the inventory of parts in the entire factory can be reduced. You can

As another embodiment of the present invention, the inventory of each process may be calculated in consideration of the number of parts used in the unfinished product on the production line. That is, since the parts used in each process of the production line are known in advance, it is possible to calculate the quantity of the parts incorporated in the unfinished product on the production line. Then, the total value of the quantity of the parts incorporated into the finished product and the quantity of the parts incorporated into the in-process products (including rejected products) on the production line, that is, the parts actually used in each process Accurate inventory quantity of parts in each process by calculating the total quantity of each part and subtracting the total quantity from the value obtained by adding the quantity of parts delivered to each process to the stock quantity of parts in each process before production starts To calculate.

By doing so, the stock quantity of each process can be known more accurately, so that it is possible to deliver the required number of parts when necessary so that no shortage of parts occurs in each process. Becomes

The present invention is not limited to the above-described embodiment, but may be configured as follows. (A) The method of reading the information for identifying the product is not limited to the method of optically reading the barcode or the like recorded on the product or the medium added to the product, and the information such as the model number recorded on the product is read. The information may be read by an image sensor or the like, or the information recorded magnetically or the information stored in a storage medium such as a contact or non-contact type IC card may be read electrically. Alternatively, an ID tag or the like having a wireless transmission function may be attached to the product to receive the ID code that identifies the product. (B) The information for specifying the product does not necessarily have to be given to each product, and the information may be notified to the production instruction computer 32 or the like when the production of the product is started. (C) If the one-time delivery quantity of parts is fixed,
The production instruction computer 23 may notify the delivery vehicle 26 of a delivery instruction each time a delivery quantity of parts is used. In this case, it is not necessary to specify the quantity in the delivery instruction. Also, if the delivery quantity for each part is different, set and manage the correspondence relationship between the part type and the delivery quantity, and compare the usage quantity of the parts used in the product with the delivery quantity of the corresponding parts. The delivery instruction may be given based on the. (D) The present invention is not limited to the conveyor type production line, and can be applied to a production system such as group production with a small number of people who does not use the line.

[0056]

According to the present invention, it is possible to accurately grasp the inventory of parts in each process. As a result, the necessary number of parts can be delivered to each process when it is necessary so as not to run out of parts. Therefore, it is not necessary to have an inventory of parts more than necessary in each process, so that the stock quantity of parts can be reduced. Further, since the kanban is not used, not only the work of creating the kanban becomes unnecessary, but also delay of delivery of parts due to time-consuming collection of kanban, and lack of parts due to loss of kanban do not occur. Further, the driver of the parts carrier can deliver the parts to each process by looking at the information about the process of the delivery destination and the parts to be delivered (for example, the name and quantity of the parts) displayed on the display device. Therefore, the efficiency of delivery work can be improved.

[Brief description of drawings]

FIG. 1 is an explanatory diagram of an inventory management method of a process according to a first embodiment.

FIG. 2 is an explanatory diagram of wireless communication of a component carrier.

FIG. 3 is a diagram showing a stop position in a production line of a component carrier.

FIG. 4 is a flowchart showing a process of a production instruction computer according to the first embodiment.

FIG. 5 is an explanatory diagram of an inventory management method of a process according to the second embodiment.

FIG. 6 is a flowchart showing a process of a production instruction computer according to a third embodiment.

FIG. 7 is an explanatory diagram of a conventional Kanban system component delivery method.

[Explanation of symbols]

21 production line 22 Bar code reader 23 Production instruction computer 25 Inventory management computer 26 parts carrier 41 Bar Code Reader 42 Host computer

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor K. Endo             2-1, Toyota-cho, Kariya City, Aichi Stock Association             Inside Toyota Toyota Industries F-term (reference) 3C100 AA45 AA47 BB02 BB05 BB21                       BB36 CC02 CC14 DD05 DD22                       DD33

Claims (7)

[Claims] 1. A product is developed into parts-level information constituting the product based on information about a product produced on a production line, and is used for a product based on the production quantity of the product and the parts-level information. An inventory management method for a process, comprising: calculating a usage quantity of each part, and calculating a stock quantity of parts in each step based on the usage quantity and information about the parts delivered to each step. 2. Based on information on a product produced in a production line, the information is expanded to parts level information constituting the product, and the product is used based on the production quantity of the product and the parts level information. Calculate the usage quantity of each part, calculate the inventory quantity of parts in each process based on the usage quantity, and the parts to be delivered to each process based on the inventory quantity and the information about the parts delivered to each step The method of instructing delivery to a component carrier, characterized in that the quantity of the component is calculated, and the information about the part to be delivered and the information indicating the process of the delivery destination of the part are displayed on the display device of the component carrier. 3. Obtaining information indicating whether or not a parts carrier stopped at a delivery destination process for delivering parts, the information indicating that the parts carrier stopped at the destination process. In the case of the above, the inventory quantity of the parts in the process is calculated based on the calculated usage amount of each part and the information about the parts delivered to the process of the delivery destination, and the information is delivered by the parts carrier. 3. The inventory quantity of the parts in the step is calculated based on the calculated usage quantity of each part when it is indicated that the process has not stopped in the previous step. Inventory management method of process or delivery instruction method to parts carrier. 4. Information for identifying a product and information for identifying a part used in the product are stored in association with each other. When the information for identifying the product is acquired, the information is stored in association with the information. 3. The parts management method according to claim 1 or 2, or the distribution to a parts carrier, by acquiring the information for specifying the parts used in the product, which is expanded to the parts level information. Instruction method. 5. A component used in the finished product and rejected product, and the quantity of the component are acquired based on information specifying a product and information on a rejected product determined to be rejected in an inspection process. Then, calculate the usage quantity of each part used in the finished product and rejected product based on the quantity of the finished product and rejected product and the number of parts used in the finished product and rejected product. Then, the parts inventory management method of the process is characterized in that the inventory quantity of the parts of each process is calculated based on the used quantity of each of the parts and the information about the parts delivered to each process. 6. The process according to claim 1, wherein the information on the parts delivered to each process includes information designating the parts and the quantity of the parts. Inventory management method or delivery instruction method to parts carrier. 7. A parts information expanding means for expanding information on parts level constituting the product based on information on a product produced on a production line, a production quantity of the product, and the parts information expanding means. Use quantity calculation means for calculating the use quantity of each part used in the product based on the part level information, and the parts of each process based on the use quantity and the information about the parts delivered to each process An inventory management system for a process, comprising: an inventory calculation unit that calculates an inventory quantity.