JP2003127036A - Production control system, work shop in cell production system, production control server, production control method, and production control program - Google Patents

Abstract

PROBLEM TO BE SOLVED: To achieve a production control technology which can automatically perform production control of products for every work shop in an assembly line of a cell production system, and also can improve production efficiency without forcing an operator to carry out any work other than proper assembling work when the operator takes out a component. SOLUTION: A production control server 131 judges taking-out of parts A, B, etc., from each of parts shelves 141A, 141B, etc., based on detected signals of passive sensors 146A, 146B, etc., for detecting a body passing through taking- out ports provided at each of a plurality of kinds of the parts shelves 141A, 141B, etc., in each of a plurality of work shops, and attains the degree of progress of the product until the completion of the assembly by making reference to the order of assembly of the parts registered in an assembly data base, and controls the number of completed products and the degree of progress of the partially fabricated product until the completion of the assembly in all work shops by registering them to a progress control data base 134.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management system, a workshop in a cell production system, a production management server, a production management method and a production management program.

[0002]

2. Description of the Related Art In an assembly line for producing a single product by combining a plurality of types of parts, a cell production system is used in which one worker is assigned to each workshop and each worker is made to perform a plurality of works. There is a production system that assembles one product from multiple types of parts.

In the assembly line of this cell production system, a large number of parts shelves are prepared for each workshop, and a plurality of kinds of parts are housed in respective predetermined parts shelves, and a worker in the workshop starts from each parts shelf. Necessary parts are taken out one after another, assembled, and sent out to the line when the assembly of one product is completed.
In this case, it is necessary to store a necessary group of parts in the parts shelf for each workshop that assembles the same product, and it is necessary to manage the parts inventory for each parts shelf in each workshop.

Therefore, for the purpose of parts inventory management and production management, each worker causes a bar code reader to read the parts taken out from the parts shelf, and the bar code data such as the part number of the parts is stored in the parts inventory management database. It may be possible to adopt a production management system that sends the data, performs processing to reduce the inventory of one part on the part shelf of the corresponding part in the corresponding workshop, and then assembles the part in the corresponding location of the product. To be

[0005]

However, the bar code attached to each of the parts taken out from the parts shelves in each workshop is read by a bar code reader, and the stock quantity of the parts is checked. In the inventory management method of reducing by one, the bar code attached to each part taken out from the parts shelf is installed not only in the worker's original assembly work but also in the bar installed at a predetermined place in each workshop. Request work to be read by a code reader. Since the procedure of reading the barcode of each part with this barcode reader is a different type of work from the work for assembling the product, the product production efficiency is impaired.

The present invention has been made in order to solve such a conventional technical problem, and it is possible to automatically perform product production control for each workshop in an assembly line of a cell production system, so that a worker can obtain parts. It is an object of the present invention to provide a production management technique capable of improving production efficiency without imposing a burden other than the original assembling work at the time of taking out.

[0007]

The invention according to claim 1 is a production management system used in a cell production system for assembling a product in which a plurality of kinds of parts are assembled in a predetermined order in each of a plurality of workshops. An assembly database for registering the assembly order of each of a plurality of types of parts used for assembling the product, a progress management database for registering the completed number of the products by all the workshops, and the degree of progress until the assembly and completion of the unfinished products, A passive sensor installed on each of a plurality of component shelves in each workshop, which detects the passage of an object through the outlet or a weight sensor which detects the weight of a stock component group, and a detection signal of the passive sensor or a weight sensor The removal of parts from each of the parts shelves is determined based on the detection signal of, and the assembly order of the parts registered in the assembly database is referred to. Serial determine the extent of progress toward assembled the finished product, but made and a production management server to be registered in the progress management database.

According to a second aspect of the present invention, in the production control system according to the first aspect, each of the workshops is provided with an alarm means, and the production control server sends a detection signal of the passive sensor or a detection signal of the weight sensor in each workshop. The suitability of the assembling order is determined based on the above, and when a component different from the regular assembling order is taken out, an alarm is output to the alarm means of the corresponding workshop.

According to a third aspect of the present invention, in the production control system according to the first or second aspect, a quality control database for registering the number of defective product stocks of defective product racks prepared for each of a plurality of types of defective events in each workshop is provided. , A passive sensor that is installed on each of a plurality of types of defective parts shelves in each workshop, that detects the passage of an object through its entrance, or a weight sensor that detects the weight of a stock parts group, the production management server, Based on the detection signal of the passive sensor or the detection signal of the weight sensor, the number of stocks of each of the defective component shelves is obtained and stored in a quality control database, and the number of defective products for each component type and each defective event is managed. It is what

According to a fourth aspect of the present invention, in the production management system according to the first to third aspects, an order file for registering product order data of a customer is provided, and the production management server orders the data in the progress management database. It is characterized in that the production progress degree with respect to the number of product orders is calculated in light of the product order data in the file.

According to a fifth aspect of the present invention, in the production management system according to the fourth aspect, the production management server transmits the production progress level information through an information network in response to a production progress level inquiry from a terminal. It is characterized by.

According to a sixth aspect of the present invention, in the production management system according to the third to fifth aspects, an ordering file for registering ordering data for each of a plurality of types of parts is provided, and the production management server is registered in the quality control database. It is characterized in that the defective product occurrence rate for each component type is obtained by comparing the data stored in the order file with the data stored in the order file.

According to a seventh aspect of the present invention, in the production management system according to the sixth aspect, the production management server responds to an inquiry about the component quality information from the terminal, and outputs defective item occurrence rate data for each component type to the information network. It is characterized by transmitting through.

According to an eighth aspect of the present invention, a passive sensor for detecting the passage of an object through the outlet or a weight sensor for detecting the weight of a stocked component group is installed on each of a plurality of types of component shelves. It is a thing.

The production management server of the invention of claim 9 is installed in each of a plurality of types of parts shelves in each of a plurality of workshops,
Extraction of parts from each of the parts shelves based on a detection signal of a passive sensor that detects passage of an object through the outlet or a detection signal of a weight sensor that detects the weight of a stock parts group of each of a plurality of kinds of parts shelves. And the assembly order of each of the multiple types of parts used to assemble the product is registered, the progress of completion of assembly of the product is calculated by referring to the assembly order of the parts registered in the assembly database. It is characterized in that it is registered in a progress management database for registering the number of completed products of the workshop and the degree of progress until the assembling of unfinished products.

According to a tenth aspect of the invention, in the production control server of the ninth aspect, the suitability of the assembly order is judged based on the detection signal of the passive sensor or the detection signal of the weight sensor in each of the plurality of workshops, and the proper assembly is performed. When a part out of order is taken out, an alarm is output to the alarm means of the corresponding workshop.

According to an eleventh aspect of the present invention, in the production management server according to the ninth or tenth aspect, an object is installed at an entrance of each of the plurality of workshops, each of which is provided on each of the defective component shelves prepared for each of a plurality of types of defective events. The number of inventories of each of the defective component shelves is calculated based on the detection signal of a passive sensor that detects passage or a weight sensor that detects the weight of the inventory component group, and the quality control database is defective for each component type and each defective event. It is characterized in that the number of parts in stock is registered.

According to the twelfth aspect of the invention, in the production management server according to the ninth to eleventh aspects, the product order data registered in the order file for registering the product order data of the customer is used by using the data of the progress management database. In light of this, it is characterized by calculating the production progress with respect to the number of product orders.

The invention according to claim 13 is characterized in that, in the production management server according to claim 12, the information on the production progress degree is transmitted through an information network in response to an inquiry about the production progress degree from the terminal. is there.

According to a fourteenth aspect of the present invention, in the production control server according to the eleventh to thirteenth aspects, the data registered in the quality control database is registered in an order file for registering order data for each of a plurality of types of parts. The feature is that the defective product occurrence rate for each component type is obtained by comparing with the order data.

According to a fifteenth aspect of the present invention, in the production control server according to the fourteenth aspect, the defective product occurrence rate for each component type is transmitted through the information network in response to the inquiry about the component quality information from the terminal. It is a thing.

According to a sixteenth aspect of the present invention, there is provided a production management method using a computer for a cell production type product assembly line for assembling a product in which a plurality of types of parts are assembled in a predetermined order in each of the plurality of workshops. A step of receiving a detection signal of a passive sensor which is installed on each of a plurality of types of parts shelves, which detects the passage of an object through the outlet, or a weight sensor which detects the weight of a stock parts group; The step of determining the taking out of the parts from each of the parts shelves based on the detection signal or the detection signal of the weight sensor, and the progress of the completion of the assembly of the product with reference to the assembly order of the parts registered in the assembly database. And registering in the progress management database.

According to a seventeenth aspect of the present invention, there is provided a production management program for causing a computer to execute production management for a cell production type product assembly line for assembling a product in which a plurality of kinds of parts are assembled in a predetermined order in each of a plurality of workshops. A process of receiving a detection signal of a weight sensor for detecting the weight of a passive sensor or an inventory part group installed in each of a plurality of types of parts shelves in each workshop, for detecting the passage of an object through the outlet, Processing for determining the takeout of parts from each of the parts shelves based on the detection signal of the passive sensor or the detection signal of the weight sensor, and referring to the assembly order of the parts registered in the assembly database until the completion of assembly of the product And a process of obtaining the degree of progress and registering it in the progress management database.

According to the eighteenth aspect of the invention, in the production control program of the seventeenth aspect, the suitability of the assembly order is judged based on the detection signal of the passive sensor or the detection signal of the weight sensor in each workshop, and the proper assembly order is determined. When different parts are taken out, it is characterized by having a process of outputting an alarm to the alarm means of the corresponding workshop.

The invention of claim 19 relates to claim 17 or 18
In the production control program, the inventory number of each defective component shelf is calculated based on the detection signal of the passive sensor or the detection signal of the weight sensor and stored in the quality control database, and the number of defective products for each component type and each defective event is stored. It is characterized by having a management process.

According to a twentieth aspect of the invention, in the production management program according to the seventeenth to nineteenth aspects, a process of comparing the data in the progress management database with the product order data in the order file to calculate the production progress rate with respect to the number of product orders is performed. It is characterized by having.

The invention of claim 21 is characterized in that, in the production management program of claim 20, in response to an inquiry about the production progress degree from a terminal, the production progress degree information is transmitted through an information network. To do.

According to a twenty-second aspect of the invention, in the production control program according to the nineteenth to twenty-first aspects, the data registered in the quality control database is compared with the data in the ordering file, and the defective product rate for each component type is calculated. It is characterized by having a process for obtaining

According to a twenty-third aspect of the present invention, in the production control program according to the twenty-second aspect, a process of transmitting defective item occurrence rate data for each of the component types through the information network in response to an inquiry about the component quality information from the terminal is performed. It is characterized by having.

[0030]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below with reference to the drawings. 1 and 2 show the configuration of the production management system of the present invention. This production management system
An assembly maker that employs an assembly line that assembles one product by combining multiple types of parts in a cell production system.
This production management system is installed at 0, and one or a plurality of parts manufacturers 20 who deliver parts, and one or a plurality of customers 3 who order products from this assembly maker 10.
0 and a telephone line, a data communication line, or both via an information network 40 constructed. In reality, the information network 40 is connected to the production management system, the terminal installed in the parts manufacturer 20 and the terminal installed in the customer 30. The assembly maker 10, the parts maker 20, and the customer 30 are connected to each other.

The production management system of the assembly maker 10 is
It is constructed by one computer system or a plurality of computer systems connected to a network, and if divided into functional configurations, an order file 111 for registering information ordered by the sales department 110 from the customer 30 and a parts procurement department 120 are provided. An order file 121 for registering the information ordered to the parts manufacturer 20, a production management server 131 operated by the production management department 130, a workshop 1, a workshop 2, a workshop 3 of the manufacturing site 140, ... Parts shelf 14 for stocking A, B, C, ...
1A, 141B, 141C, ..., Defective part shelves 142A, 142 for dividing and stocking defective parts by defect event
B, ..., Transmission devices 144, 14 for transmitting signals from these parts shelves 141A, 141B, ... And defective part shelves 142A, 142B, .. to the production management server 131 through an in-house network 143 such as a LAN or an intranet.
It consists of 5. In addition, an alarm device 148 is installed in each workshop to notify the operator that the assembly order is incorrect.

The production control server 13 of the production control department 130
1 includes a quality control database 132, an assembly database 133, and a progress management database 134 on a storage device having a built-in or LAN connection, and an assembly sequence monitoring function unit 135 as a processing function that is exhibited by executing a program. , An assembly failure notification function 136, and a workshop-specific assembly performance management function unit 137. The production management server 131 further includes a shelf address database 138 on a storage device also incorporated therein or connected to a LAN.

In the order file 111 of the sales department 110, for example, data such as customer name, order number, product name (commodity name), delivery date and quantity are registered. Parts procurement department 120
In the ordering file 121 of, for example, data such as an orderer name, a part name (part number), a destination (embedded product name), an ordering quantity, a delivery date, a receiving time, a defective product quantity, a defective return time, and the like are registered.

In the quality control database 132 connected to the production control server 131, for example, data such as the parts manufacturer name, the parts name, the failure occurrence date and time, the occurrence quantity, the failure phenomenon, and the countermeasure contents are registered. Assembly database 133
For example, data such as a product name, an assembly order, a built-in part name, a part maker name, and an assembly standard time are registered.

In the progress management database 134 of the production management server 131, for example, the order number, the product name, the line name, and the progress status of each product (start time;
Process 1 execution time; process 2 execution time; ...; completion time), production quantity, production progress degree for each order number, and other data are registered. The production progress is obtained by the ratio of the actual production quantity of each product to the order production quantity of each product.
In addition, the degree of progress with respect to the production plan is the assembly database 1
Based on the assembly standard time registered in 33, the current production volume is calculated, and this is calculated by comparing this with the actual production volume.

As shown in detail in FIG.
Each of the workshops 140x (x is the x-th of all the workshops) has a plurality of parts A, B, C, D, ... Parts shelves 141A, 141B, 141C, 1 stocked therein.
41D, ..., Defective product shelves 142A, 142B, 142 that stock defective products for each of defective events A, B, C, D ,.
C, 142D, ... Are installed. Then, a passive sensor 146A that senses when an object passes through an outlet of each of the component shelves and an inlet of each of the defective product shelves,
146B, ...; 147A, 147B ,. And these passive sensors 146A, 146
B, ...; 147A, 147B, ... Sensing signals are transmitted to the production control server 131 of the production control section 130 through the network 143 by the transmission devices 144 and 145. This sensing signal is a signal for notifying the parts shelf address. The passive sensor is an infrared sensor, a light sensor, or a light-emitting element and a light-receiving element that are installed so that the light-emitting element and the light-receiving element are separated from each other and that the signal light is blocked by an object that enters between them. It is possible to use an infrared sensor or an optical sensor in which the element and the element are installed at the same position, and the light receiving element detects the reflected light that is returned when the signal light from the light emitting element is applied to the object.

As shown in the table of FIG. 3, the production control department 13
In the shelf address database 138 connected to the production management server 131 of 0, the address of each part shelf of each workshop and the part number stocked there, the address of each defective product shelf and the defective event of that shelf are stored. The data corresponding to is stored in advance. Therefore, if the passive sensor 146x of a certain shelf 141x senses the passage of a component and sends the shelf address signal to the server 131, the server 131 refers to the table of this shelf address database 138 and determines the received shelf address. It is possible to specify the name of the part that was originally taken out. For example, when the sensing signal of the shelf address 02 is input, it is determined that the part number is the B part 20012. Further, when the sensing signal of the shelf address 103 is input, it is determined that the component taken out immediately before on the shelf of the defective event B is stored as the defective component.

Next, the production control method in the cell production system by the production control system having the above configuration will be described with reference to the flow charts of FIGS. 4 and 5. Data such as that shown in FIG. 3 is registered in advance in the shelf address database 138 of the production management department 130 prior to the production of a certain product.
In the assembly database 133, the assembly order of parts is registered for each product. For example, as shown in FIG.
As for the product A, in the first step, the part A is taken out from the shelf and prepared, in the second step, the part B is taken out from the shelf and attached to the part A, and in the third step, the part C is taken out from the shelf.
A table that associates an assembly step with a part name (actually managed by a part number) used in each step, such as taking out and assembling the part A, is registered in the assembly database 133 ( Step S0
1).

In assembling the product A, the server 131 extracts the part number used in the first step from the assembly order master file of the product A in the assembly database 133 (step S11).

When an assembling worker of a certain workshop (here, the workshop 3) takes out the part A from the parts shelf 141A, the operator's hand once enters the entrance of the parts shelf 141A and takes out the parts by a passive sensor. 146A detects (step S21). The transmission device 144 converts the sensing signal of the passive sensor 146A into a shelf address and transmits it to the server 131, and the server 131 receives the shelf address and detects the time (step S22). Server 13
1 further refers to the shelf address database 138 to determine whether the received shelf address is the shelf address of the defective component shelf (step S23).

If it is determined in step S23 that the input shelf address is the shelf address of the parts shelf, the part number stored in the shelf address is extracted and the part number used in the first step extracted in step S11 is used. The assembly order is collated depending on whether or not they match (step S24).

If the collation of the assembly order in step S24 is not established, it is considered that the worker of the workshop 3 has taken out the wrong part, and an alarm command is transmitted to the workshop 3 via the transmission device 144, and the alarm 148 is issued. To output an alarm (steps S25 and S26).

When the collation of the assembling order in step S24 is established, a flag indicating that the first assembling step of the product A is completed is set and the assembly database 133 is notified (steps S25 and S27). As a result, the server 131 extracts the information of the second step, which is the next step, from the assembly database 133 in step S11, and repeats the same processing thereafter. The same applies to the third and subsequent steps.

Following step S27, the above-mentioned sensing time is recorded in the progress management database 134 as the first step completion time for the product A in the workshop 3 (step S28). Similar processing is executed for the second and subsequent steps. The registration data of the progress management database 134 is used for grasping the progress status described later.

When the shelf address of the passive sensor 146x that senses the passage of the object corresponds to the shelf address of the defective product shelf, the process branches to YES in step S23 and shifts to the defective product management process. There, first, the assembly step immediately before the workshop 3 is extracted as a defect target step from the data in the assembly database 133 (step S31). Then, the defective target part is specified from the part number corresponding to the immediately preceding take-out shelf address (step S32), the defective event is specified from the shelf address in which the defective part is stored, the occurrence time is detected, and the quality control is performed. It is registered in the database 132 (step S33). Therefore, this quality control database 13
7, the defective part number, the defective part name, etc. are registered for each of the defective events A, B, C, ... As shown in FIG. The data of the quality control database 132 is used for part quality control described later.

After the failure target step is extracted in step S31, it is necessary to take out the necessary parts from the corresponding parts shelf again in the same assembly step. Therefore, the assembly database 13
The defect target step of the workshop 3 of 3 is cleared (step S34), and the workshop 3 of the progress management database 134 is also cleared.
The record of the completion time of the assembly step immediately before is deleted, the process returns to step S11 again, and the work is restarted from the assembly of the same part as the defective product (step S35). Note that step S
The processes of 32, S33 and steps S34, S35 may be executed concurrently in parallel, or one of them may be executed in sequence prior to the other.

The progress status in step S02 can be grasped by displaying the screen 1310 shown in FIG. 8 on the display 139 connected to the server 131. This screen 1310 is output by the server 131 automatically searching the order file 111 and the progress management database 134 when the user designates the order number and instructs the progress status output. Here, the result of designating the order form number 1234567 is shown, but the customer name, delivery date, ordered product name, and the number of orders linked from this order form number are picked up from the order file 111 and output to the corresponding column. Further, from the progress management database 134, the number of parts set, the number of start (number of completed first step), the number of completed step 01 (second step), and the number of completed step 2 (third step) for each applicable product (product). ..., the number of finished products,
Further, the number of warehouses and the number of shipments are read out and output in a predetermined form, for example, the illustrated graph format. Here, when the customer's computer inquires about the progress status through the information network 40, the server 131 executes the process shown in FIG.
It is possible to transmit the screen information of the above to the inquiry source computer and display it on the screen of the customer's computer. By building this network system,
It is possible for the customer to grasp the production progress status of the ordered product in real time.

The grasp of the defect information in step S03 is performed by displaying the screen 1311 shown in FIG. 9 on the screen of the display 139 connected to the server 131. This screen 1311 displays defect information for each component manufacturer and each component. When the user instructs the server 131 to output the defect information by designating the part number, the server 131 accesses the ordering file 121 and supplies the part manufacturer of the corresponding part, the part name, the delivery date, and the quantity. And the quality control database 132 is accessed to pick up the total number of used parts and the number of defective parts, and also to pick up the corresponding number for each defective event in a predetermined format, for example, the illustrated graph format. Output. In addition, product manufacturer 10
If the system in which the server 131 transmits the screen information to the component manufacturer 20 side informing the defect status via the information network 40 or the server 131 transmits the screen information in response to the inquiry from the component manufacturer 20 side, the defective product can be obtained. The situation of occurrence of can be notified in real time, can be reflected in quality control of parts, and shortage of parts can be procured on time.

As described above, according to the production management system of the first embodiment, the worker does not need to register the extracted parts in the system with the bar code reader every time the parts are taken out, and the work can be performed. An operator can automatically register the extracted parts in the system simply by sequentially taking out the necessary parts from each parts shelf, and when a defective part occurs, the worker is prepared for each defective event. The system can automatically register the part number, part name, and defect event of the defective part in the system simply by storing it in a specified shelf, which reduces the burden on the worker who works in each workshop, while managing production and parts. Quality control is possible.

In addition, a parts manufacturer and a product order recipient (customer)
By connecting this system with the information network via the information network, it is possible to notify the customer in real time of the production progress status of the ordered product, and improve the service. In addition, the defective information such as the occurrence rate, defective event, and defective quantity of defective parts can be obtained. Can be notified to the parts manufacturer, the quality of the parts can be improved, and on-time procurement of missing parts can be achieved.

The workshop-based assembly record management function 137 of the production management server 131 in the management department 130 manages the assembly completion record for each workshop registered in the progress management database 134. The production management server 131 also has a function of managing the total number of productions of each product by using the data of the progress management database 134 and adding up the number of products completed for each product and for each workshop.

Next, a production management system according to the second embodiment of the present invention will be described with reference to FIG. 1, FIG. 2, FIG. The feature of the second embodiment is that the component shelves 141A, 141B, ... For each workshop in the manufacturing site 140, the defective shelves 142A, 142B ,. Instead, a weight sensor is installed, and other configurations are common to the first embodiment.

By installing a weight sensor on each of the parts shelves and a defective product shelf, in the case of each of the parts shelves, the weight of the parts is reduced by the signal from the weight sensor to judge the parts take-out. In the case of each defective item shelf, the weight is increased by the weight of the component in response to the signal from the weight sensor to determine whether the item is stored as a defective item.

In the production management system of the second embodiment, the server 131 carries out production management by the processing shown in the flowcharts of FIGS. 10 and 5. Similar to the first embodiment, the data shown in FIG. 3 is registered in the shelf address database 138 of the production management department 130.
Further, the assembly order of the parts is registered for each product in the assembly database 133 (step S01).

In assembling the product A, the server 131
Extracts the part number used in the first step from the assembly order master file of the product A in the assembly database 133 (step S11).

When an assembling operator of a certain workshop (also referred to as the workshop 3) takes out the component A from the component shelf 141A, the rack weight is reduced by the weight of the component, so that the transmission device 144 is used.
Grasps the weight change (step S21 '), and transmits the changed weight of the weight sensor 146A, the change occurrence time, and the shelf address to the server 131 (step S22').

The server 131 is a shelf number database 13
8, it is determined whether the received shelf address is the shelf number of the defective component shelf (step S23).

If it is determined in step S23 that the input shelf address is the shelf address of the parts shelf, the part number stored in that shelf address is extracted and the part number used in the first step extracted in step S11 is used. The assembly order is collated depending on whether or not they match (step S24).

If the collation of the assembly order in step S24 is not established, it is considered that the operator of the workshop 3 has taken out the wrong part, an alarm command is transmitted to the workshop 3 via the transmission device 144, and the alarm 148 is issued. To output an alarm (steps S25 and S26).

When the collation of the assembling order in step S24 is established, it is then confirmed whether or not the changed weight is one corresponding part (steps S25 and S251). This step S2
If the changed weight is not one corresponding part in 51, it is considered that double removal has been performed, an alarm command is issued, and an alarm is output from the alarm device 148 (steps S251 and S2).
6).

On the other hand, if it is determined in step S251 that the changed weight is for one relevant part, a flag indicating that the first assembly step of the product A is completed is set and the assembly database 133 is notified (step 27). . As a result, the server 131 extracts the information of the second step, which is the next step, from the assembly database 133 in step S11, and repeats the same processing thereafter. The same applies to the third and subsequent steps.

In addition, following step S27, the above-mentioned weight change sensing time is stored in the progress management database 134.
Is recorded as the first step completion time for the product A in the workshop 3 (step S28 '). Similar processing is executed for the second and subsequent steps. The registration data of the progress management database 134 is used for grasping the progress status as in the first embodiment.

If the shelf address of the weight sensor 146x that senses the weight change of the shelf corresponds to the shelf address of the defective product shelf,
In step S23, the process branches to YES, and similarly to the first embodiment, the defective product management process shown in the flowchart of FIG. 5 is performed. That is, the assembly step immediately before the workshop 3 is extracted from the data of the assembly database 133 as the defect target step (step S31), and the defective target part is identified from the part number corresponding to the immediately preceding take-out shelf address (step S3).
2) Further, the defective event is specified from the shelf address in which the defective part is stored, the occurrence time is detected, and registered in the quality control database 132 (step S33). The data of the quality control database 132 is used for part quality control, as in the first embodiment.

After the defect target step is extracted in step S31, it is necessary to take out the necessary parts from the corresponding parts shelf again in the same assembly step.
The defect target step of the workshop 3 of 3 is cleared (step S34), and the workshop 3 of the progress management database 134 is also cleared.
The record of the completion time of the assembly step immediately before is deleted, the process returns to step S11 again, and the work is restarted from the assembly of the same part as the defective product (step S35). Here again, there is no particular limitation before or after the processing of steps S32, S33 and steps S34, S35.

As described above, also in the production management system of the second embodiment, the worker does not require the labor of registering the extracted parts in the system by the bar code reader every time the parts are taken out, and Can automatically register the extracted parts in the system simply by performing the work of sequentially extracting the necessary parts from each of the parts shelves, and when a defective part occurs, a worker is prepared for each defective event. You can automatically register the part number, part name, and defect event of a defective part in the system simply by storing it in a predetermined shelf, reducing the burden on the workers who work in each workshop, while maintaining production control and part quality. Can be managed.

In addition, a parts manufacturer and a product order receiver (customer)
By connecting this system with the information network via the information network, it is possible to notify the customer in real time of the production progress status of the ordered product, and improve the service. In addition, the defective information such as the occurrence rate, defective event, and defective quantity of defective parts can be obtained. Can be notified to the parts manufacturer, the quality of the parts can be improved, and on-time procurement of missing parts can be achieved.

[0067]

As described above, according to the present invention, it is possible to automatically perform product production management for each workshop in an assembly line of a cell production system, and to allow an operator to perform other than the original assembly work when taking out parts. The production efficiency can be improved without imposing a burden.

[Brief description of drawings]

FIG. 1 is a block diagram showing a configuration of a production management system according to an embodiment of the present invention.

FIG. 2 is a block diagram showing a system configuration of a manufacturing site in the above embodiment.

FIG. 3 is a data structure diagram of a shelf number database in the above embodiment.

FIG. 4 is a flowchart of a production management process according to the above-described embodiment (Part 1).

FIG. 5 is a second flowchart of the production management process according to the above embodiment.

FIG. 6 is a data structure diagram of the assembly database in the above embodiment.

FIG. 7 is a data structure diagram of the quality control database in the above embodiment.

FIG. 8 is an explanatory diagram showing a screen example of a production progress situation by customer order displayed by the production management server or the customer terminal in the above embodiment.

FIG. 9 is an explanatory diagram showing an example of a screen of component-specific defect information for each component displayed by the production management server or the terminal of the component manufacturer in the above embodiment.

FIG. 10 is a flowchart of production management processing according to the second embodiment of the present invention.

[Explanation of symbols]

10 Assembly manufacturer 20 parts manufacturers 30 customers 40 Information network 110 Sales Department 111 Order file 120 Procurement Department 121 Order file 130 Production control department 131 Production management server 132 Quality control database 133 Assembly database 134 Progress management database 135 Assembly order monitoring function 136 Assembly failure notification function 137 Assembly result management function by workshop 138 shelf number database 140 manufacturing sites 141A, 141B, ... Parts shelf 142A, 142B, ... Defective shelf 143 LAN 144 transmission device 145 Transmission device 146A, 146B, ... Passive sensor 147A, 147B, ... Passive sensor 148 alarm A, B, C, ... Parts

Continued front page    F-term (reference) 3C030 DA01 DA02 DA04 DA10                 3C100 AA29 AA32 AA56 AA65 BB02                       BB27 BB33 BB36 BB38 BB39                       CC02 CC08

Claims (23)

[Claims] 1. A production management system used in a cell production system for assembling a product in which a plurality of kinds of parts are assembled in a predetermined order in each of a plurality of workshops, and a plurality of kinds of parts used for assembling the product. An assembly database for registering each assembly sequence, a progress management database for registering the number of completed products of all workshops and the progress of assembly of unfinished products, and installation on each of multiple types of parts shelves in each workshop A weight sensor that detects the weight of a passive sensor or an inventory part group that detects the passage of an object through the outlet, and from each of the parts shelves based on the detection signal of the passive sensor or the detection signal of the weight sensor. Determining the removal of each part, and referring to the assembly order of the parts registered in the assembly database, the degree of progress until the assembly of the product is completed. Demand,
A production management system comprising: a production management server registered in the progress management database. 2. Each of the workshops is provided with an alarm means, and the production management server determines whether or not the assembly order is proper based on a detection signal of the passive sensor or a detection signal of the weight sensor in each workshop, and a proper assembly order. The production management system according to claim 1, wherein an alarm is output to the alarm means of the workshop when a component different from the above is taken out. 3. A quality control database for registering the number of defective product inventories of defective product shelves prepared for each of a plurality of types of defective events in each workshop, and a plurality of defective component shelves installed in each workshop. A weight sensor that detects the weight of a passive sensor or an inventory part group that detects an object passing through the entrance, and the production management server, based on the detection signal of the passive sensor or the detection signal of the weight sensor, 3. The production management system according to claim 1, wherein the number of stocks of each defective component shelf is calculated and stored in a quality control database, and the number of defective products is managed for each component type and each defective event. 4. An order file for registering product order data of a customer is provided, wherein the production management server compares the data of the progress management database with the product order data of the order file to show the production progress degree with respect to the number of product orders. The production management system according to claim 1, wherein the production management system is calculated. 5. The production management system according to claim 4, wherein the production management server transmits the production progress information through an information network in response to a production progress inquiry from a terminal. 6. An ordering file for registering ordering data for each of a plurality of types of parts is provided, and the production management server compares the data registered in the quality control database with the data in the ordering file, for each part type. 6. The production management system according to claim 3, wherein the defective product occurrence rate is obtained. 7. The production management server transmits data of defective product occurrence rate for each component type through an information network in response to an inquiry about component quality information from a terminal. production management system. 8. A workshop in a cell production system in which a passive sensor for detecting the passage of an object through a take-out port or a weight sensor for detecting the weight of a stock component group is installed on each of a plurality of types of component shelves. 9. A detection signal of a passive sensor, which is installed on each of a plurality of types of parts shelves in each of a plurality of workshops and detects passage of an object through an outlet, or a stock parts group of each of a plurality of types of parts shelves. It is registered in the assembly database that determines the removal of parts from each of the parts shelves based on the detection signal of the weight sensor that detects the weight, and registers the assembly order of each of the multiple types of parts used to assemble the product. Obtain the degree of completion of assembly of the product by referring to the assembly order of parts, and register in the progress management database that registers the number of completed products of all workshops and the progress of assembly of unfinished products to completion. Production management server characterized by. 10. The warning of the corresponding studio is determined when the suitability of the assembly order is judged based on the detection signal of the passive sensor or the detection signal of the weight sensor in each of the plurality of studios and a part different from the regular assembly order is taken out. The production management server according to claim 9, wherein the means outputs an alarm. 11. The weight of a passive sensor or an inventory part group installed in each defective part shelf prepared for each of a plurality of types of defective events in each of the plurality of workshops and detecting the passage of an object through its entrance is detected. 10. The inventory number of each of the defective component shelves is calculated based on the detection signal of the weight sensor, and the inventory number of defective components is registered in the quality control database for each component type and each defective event. The production management server according to item 10. 12. The production progress rate with respect to the number of product orders is calculated by using the data of the progress management database and by comparing the product order data registered in the order file for registering the product order data of the customer. Claim 9
The production management server according to any one of 1 to 11. 13. The production management server according to claim 12, wherein the production progress information is transmitted through an information network in response to a production progress inquiry from a terminal. 14. The defective product occurrence rate for each part type is obtained by comparing the data registered in the quality control database with the order data registered in an order file that registers order data for each of a plurality of types of parts. The production management server according to any one of claims 11 to 13, characterized in that. 15. The number of defective products for each component type and / or the defective product occurrence rate is transmitted through an information network in response to an inquiry about component quality information from the terminal or by designating a predetermined terminal. The production management server according to claim 14. 16. A production management method using a computer for a cell production type product assembly line for assembling a product in which a plurality of kinds of parts are assembled in a predetermined order in each of a plurality of shops, wherein a plurality of kinds of parts of each workshop are provided. A step of receiving a detection signal of a passive sensor which is installed on each of the shelves and detects a passage of an object through the outlet or a weight sensor which detects the weight of a stock component group; and a detection signal of the passive sensor or a weight sensor The step of determining the taking out of the parts from each of the parts shelves based on the detection signal of the step, and referring to the assembling order of the parts registered in the assembling database, obtaining the degree of progress until completion of the assembling of the product, And a step of registering in a database. 17. A production management program for causing a computer to execute production management for a cell-manufactured product assembly line for assembling a product in which a plurality of types of parts are assembled in a predetermined order in each of the plurality of workshops, A process of receiving a detection signal of a passive sensor which is installed on each of the various kinds of parts shelves and which detects an object passing through the outlet or a weight sensor which detects the weight of a stock parts group, and the detection signal of the passive sensor Alternatively, the process for determining the take-out of parts from each of the parts shelves based on the detection signal of the weight sensor and the progress of completion of the assembly of the product are referred to by referring to the assembly order of the parts registered in the assembly database. , A production management program having a process of registering in a progress management database. 18. The suitability of the assembly order is judged based on the detection signal of the passive sensor or the detection signal of the weight sensor in each workshop, and when the parts different from the regular assembly order are taken out, the alarm means of the corresponding workshop is provided. The production management program according to claim 17, further comprising a process of outputting an alarm. 19. The number of inventories of each defective component shelf is obtained based on the detection signal of the passive sensor or the detection signal of the weight sensor and stored in a quality control database, and the number of defective products for each component type and each defective event is managed. The production management program according to claim 17, further comprising: 20. The method according to claim 17, further comprising a process of comparing the data of the progress management database with the product order data of the order file and calculating the production progress degree with respect to the number of product orders. Production management program. 21. The production management program according to claim 20, further comprising a process of transmitting the production progress level information through an information network in response to a production progress level inquiry from a terminal. 22. The method according to claim 19, further comprising the step of comparing the data registered in the quality control database with the data in the ordering file to obtain the defective product occurrence rate for each component type. The production control program described in Crab. 23. The production control according to claim 22, further comprising a process of transmitting defective item occurrence rate data for each component type through an information network in response to an inquiry about component quality information from a terminal. program.