JP2003195932A - Production adjusting system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production adjusting system capable of effectively adjusting the production of an unfinished product with respect to the discontinuation of order reception. <P>SOLUTION: The quantity of work of an intermediate product in a previous process is determined on the basis of the necessary time for producing the intermediate product and the production quantity of the products in the previous process, and the stock quantity of the final product and that of the intermediate product are respectively determined. The quantity of work in process of the intermediate product in the previous process is appropriated and controlled (quantity of work control means) in accordance with the order reception scheduled quantity of the product, and the date for discontinuing the start of production of the intermediate product is determined (adjustment of production start) in accordance with the stock quantities of the final product and the intermediate product, and the quantity of work of the intermediate products, when the order reception schedule of the product is discontinued. In particular, the stock quantities of the final product and the intermediate product are respectively fitted to the total quantity of the order reception products, and the date for discontinuing the start of work in process of the intermediate product is determined on the basis of the shortage in fitting and the quantity of work in process of the intermediate product. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production adjustment system capable of optimizing the in-process amount of an intermediate product produced prior to receiving an order for a final product.

[0002]

2. Related Background Art A variety of equipment, for example, a wire harness to be incorporated in an automobile has a plurality of wire harnesses (for example, 200 to 30) according to a wiring pattern determined according to its specifications.
(0 pieces) of wire rods are laid and bundled. Further, in this type of wire harness, connecting parts such as connectors are attached to the ends of the respective wire members, and the number of these parts is 100 to 200 per wire harness.
It reaches to individual.

In the manufacture of such a wire harness, generally, a designated wire is cut into a predetermined length according to the specifications of various wire rods derived from the specifications of the wire harness, and a predetermined length is cut at both ends of the wire. Multiple types of wire components (single wire) are manufactured by mounting (crimping) the terminal members [cutting pressure step]. After that, for each predetermined group in the wire harness, a plurality of wire components (single wire material) that form the group are bundled, and each terminal member of these wire components is fitted into a predetermined connector to form a plurality of intermediate products. Assembling each kind of temporary wire [temporary bonding process].
After that, these temporary connection wires are laid according to the wiring patterns given as specifications of the wire harness, and then the temporary connection wires are bundled to assemble the wire harness [assembly step].

When manufacturing a wire harness in this way, the period from the confirmation of the order of the wire harness to the delivery date thereof is generally relatively short.
The order quantity is predicted in advance, an intermediate product (temporary wire material) is manufactured in advance, and it is prepared as an in-process product.

[0005]

When the intermediate product (temporary wire material) is manufactured as a work-in-progress as described above,
It is undeniable that a large amount of work-in-progress causes a heavy physical and financial burden. Therefore, if the production management is performed so as to manufacture the intermediate products corresponding to the order quantity of the products, the in-process quantity can be minimized. However, it is difficult to accurately predict the order quantity of products, and it is very difficult to optimize the in-process quantity of intermediate products in anticipation of fluctuations in the order quantity.

Particularly in a wire harness production line, it is necessary to manufacture a plurality of types of wire parts according to the specifications of the wire harness in the cutting pressure step described above, before assembling a temporary wire material as an intermediate product. Is. Therefore, even if the order quantity of products is predicted and the manufacture of the intermediate product is instructed, the intermediate product cannot be manufactured unless a plurality of types of wire parts are manufactured prior to the manufacturing of the intermediate product.

By the way, in the cutting process, a plurality of production lines (cutting machines) for producing wire parts according to the parts specifications are usually provided in parallel, but compared to the number of manufacturing lines (cutting machines). Then, the types of wire rods incorporated in the wire harness are extremely huge. In addition, there are often restrictions on the manufacturing line (cutting machine) capable of cutting pressure the wire rod due to the thickness of various wire rods, and there is also a difference in the manufacturing (processing) capability. Therefore, it is necessary to properly set up which wire parts are to be manufactured on which manufacturing line (cutting machine), that is, so-called splicing. It is necessary to individually manage the production of multiple types of wire components according to the status of the difference in the process.

Even if the order quantity of the product is accurately predicted, if the fluctuation of the order quantity is large, the in-process quantity of the intermediate product is adjusted according to the production capacity of the manufacturing line (cutting machine). Will be required. In particular, when it is expected that the order will be discontinued (production discontinuation), there is a problem of how to adjust the amount of intermediate products in process until the order is discontinued.

The present invention has been made in view of the above circumstances, and its purpose is to manage the production of parts necessary for producing an intermediate product, as represented by the manufacturing process of a wire harness, for example. It is necessary to adjust, even in the production line, it is possible to easily optimize the in-process amount of the intermediate product according to the fluctuation of the order of the final product, and it is possible to effectively deal with the discontinuation of the order in particular. To provide a production adjustment system.

[0010]

In order to achieve the above-mentioned object, the production adjusting system according to the present invention comprises a pre-process for producing an intermediate product which is a part of the final product as a work-in-progress, and the intermediate process according to an order received. It is suitable for application to a production line consisting of a post-process for producing a final product by using a product, and the production time (lead time; L / T) of the intermediate product in the previous process and the product production amount ( In-process amount detection means for obtaining the in-process amount of the intermediate product in the previous process from (lot size x number of lots), and the inventory amount of the final product produced in the subsequent process and the inventory amount of the intermediate product produced in the previous process. Inventory control means required for each, in-process quantity control means for optimizing the in-process quantity of intermediate products in the previous process according to the expected order quantity of the final product, and when an order interruption of the final product is expected It said final accordance with product and the stock amount of the intermediate product and progress amount of the intermediate product, is characterized in that a production start adjusting means for stopping the progress start of the intermediate product.

Preferably, the in-process amount control means sets an appropriate in-process amount (in-process amount) of the intermediate product in the preceding process (in-process amount setting means) according to the expected order quantity of the final product, and the in-process amount. The production amount of the intermediate product in the preceding process is adjusted according to the in-process amount of the intermediate product obtained by the detection means and the appropriate in-process amount (in-process circulation amount control means).

Further, the production start adjusting means obtains the total amount of the final products to be shipped before the order is discontinued, allocates the stock amounts of the final products and the intermediate products to the total amount, respectively, and obtains the deficiency thereof. The in-process start of the intermediate product is controlled to be stopped by the control of the in-process amount control means according to the shortage amount and the in-process amount of the intermediate product in the preceding process.

The production of the intermediate product in the preceding step is performed in lot units with a predetermined number of intermediate products as one lot, and the work-in-process control means increases or decreases the number of lots and / or lot size to produce the product. Is configured to adjust. Further, when the preceding step includes a preparatory step of manufacturing a plurality of types of parts necessary for the production of the intermediate product, the work-in-progress control means respectively determines the production amounts of the plurality of kinds of parts in the preparatory step according to the in-process proper amount. It is configured to activate the adjustment splicing system and control the production amount of the intermediate product in accordance with the production amounts of the plurality of types of parts in this preparation process.

By the way, the post-process in the production line is for producing a wire harness as a final product, and the pre-process for producing an intermediate product as a work-in-progress is performed for each predetermined unit in the wire harness. And a connector is attached to the ends of these wire components to produce a temporary wire assembly. Then, the production adjustment of the temporary wire material at the time of discontinuing the order is executed by stopping the production start of the wire parts necessary for producing the temporary wire material.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a production adjustment system according to an embodiment of the present invention will be described with reference to the drawings by taking an example of manufacturing a wire harness. FIG. 1 shows an overall schematic configuration of a production line in which this production adjustment system is incorporated. This production line roughly includes a preparatory step (processing step) 1 for manufacturing parts, and a pre-process (accumulation step for accumulating the parts supplied from the preparatory step 1 to form an intermediate product) Step 2) and a post-step (assembly step) 3 in which the final product is completed by using the intermediate product manufactured in the pre-step 2. The preparation step 1 and the previous step 2
Prior to receiving an order for a product, expects the amount of the order, and manufactures the parts required for manufacturing the final product, and further manufactures an intermediate product in which these parts are integrated as a work-in-process. Further, in the post-process 3, for example, a final product is manufactured according to an order received.

In the wire harness manufacturing line, the preparation step 1 is to cut a specified wire material into a predetermined length according to the specifications of various wire materials of the final product wire harness, and to attach a predetermined terminal to each end. It consists of a cutting and splicing process in which multiple types of wire components (single wire) are manufactured by mounting (pressing) members. Then, in the cutting pressure / splicing process (preparing process) 1, for example, the production time is 3 days (L / T) according to the picture mark 1a issued according to the in-process circulation amount operation of the intermediate product described later.
= 3), the line parts required to produce the intermediate product are manufactured. Incidentally, the picture mark 1a is attached to the line component and sent to the previous step 2 when the production of the line component is completed. At this time, the information of the line parts described in the above-mentioned picture mark 1a is read as the production completion information, and the processing progress management section database (D
B) Registered in 4.

On the other hand, in the preceding step 2, a plurality of wire parts (single wire) forming a predetermined unit in the final product wire harness are used by using the plurality of kinds of wire parts manufactured in the above-mentioned preparation step 1. (A material) is bundled, each terminal member mounted on each of these wire components is fitted into a predetermined connector, and a plurality of types of temporary connection wire materials as intermediate products are assembled respectively. This pre-process (temporary binding process) 2 includes a processing progress management database (DB) 4
The temporary wire is manufactured according to the wire rod payout table (temporary wire material specification sheet) 2a issued under the control by, for example, the production required time is 1 to 4 days (L / T = 1 to 4). Is set as.

The post-process 3 is an assembly process for assembling a wire harness, which is a final product, using a temporary wire, and the production time is, for example, 3 days (L / T = 3).
Is set as. This assembling step (post-step) 3 is a temporary-bonding progress management database (D) that manages the manufacturing progress status of the temporary wire material in the temporary-bonding step (previous step) 2.
B) Temporary statement statement 5a issued by 5 and temporary statement list 5
According to b, the temporary connection wire rods produced in the temporary connection step (previous step) 2 are collected to assemble a wire harness having a predetermined product specification.

The wire rod dispensing table (temporary wire rod specification sheet) 2a attached to the temporary wire rod is collected when the temporary wire rod is used in the assembling process (post process) 3, and The described information is the processing progress management database (DB) 4
Be registered with. This wire rod payout table (temporary wire rod specifications) 2a
By collecting, the in-process amount of the temporary wire material, which is an intermediate product, is managed from the number of wire material issue tables (temporary wire material specification sheet) 2a currently issued. At the same time, the inventory quantity of work in progress (intermediate products) is managed.

The production adjustment system optimizes the in-process amount of the intermediate product (temporary wire material) in the production line of such a product, and is constructed by a computer system or the like. In particular, this production adjustment system is a temporary binding process (preceding process)
In-process circulation amount management means 11 for managing the in-process amount of the temporary wire material (intermediate product) manufactured in 2 and obtaining the in-process amount as the in-process circulation amount, and the intermediate product in accordance with the order information of the final product (wire harness). And an in-process set amount setting means 12 for setting an optimum in-process amount. Then, the in-process circulation amount is used as a control amount, and the optimal in-process amount is set as a set amount to obtain an in-process operation amount and apply it to the in-process circulation amount operation unit 13 to perform the in-process circulation in the preparation process (cutting pressure / spline process) It is equipped with a feedback control system that operates the quantity (lot number). This work-in-process circulation amount (number of lots) is operated by operating the above-mentioned issuing of the picture mark 1a.

By the operation of the in-process circulation amount (the number of lots) by the feedback control system as described above, the temporary connection wire (intermediate) manufactured by the temporary connection process (previous process) 2 through the cutting pressure / spline process (preparation process) 1 The in-process amount of the product) is optimized and controlled in accordance with the set circulation amount (appropriate amount of work) set according to the order information (estimated order amount) of the wire harness (final product).

On the other hand, this production adjustment system starts production according to the order information of the final product, particularly the planned order quantity, in addition to the feedback control system for optimally controlling the in-process quantity of the temporary wire (intermediate product) described above. Under the control of the production start adjusting process in the adjusting means 14, the issuing date and time of the picture mark 1a in the cutting pressure / splicing process (preparing process) 1, that is, the production starting date and time of the line parts is adjusted, and further the production start is stopped. It is equipped with a feedforward control system.

The production start adjustment processing by the production start adjustment means 14 is basically whether or not the order quantity fluctuates at the unshown stage prior to final confirmation of the order, and further whether or not the order is discontinued. Is done by examining. If the order is not discontinued, the assembly process (post process) is performed.
The stock amount of the wire harness (final product) manufactured in 3 and the stock amount of the temporary bonding part (intermediate product) manufactured in the temporary bonding process (preliminary process) 2 are examined to determine the wire harness (final product). ) Of the intermediate product (temporary wire material) is judged to be in excess or deficiency according to the planned order quantity of), and the in-process quantity is adjusted according to the excess or deficiency of the in-process quantity. We are looking for a production start date and time (recommended finish time) that is suitable for starting production of a product.

The recommended production period is the time required for production (lead time) of the temporary bonding component (intermediate product) in the temporary bonding process (pre-process) 2 and the wire harness (final product) in the assembly process (post-process) 3. In consideration of the production required time (lead time), it is obtained as the production start date and time of the intermediate product necessary for manufacturing the final product by the order delivery date.
When the order is discontinued, the production start adjustment processing means 14 obtains the total amount of the final products to be produced before the discontinuation, and the wire harness (the final product) manufactured in the assembling process (post process) 3 is finished. ) And the stock amount of the temporary bonding parts (intermediate products) manufactured in the temporary bonding process (previous process) 2 and further, the amount of the temporary bonding parts (intermediate products) in process (work in process). Circulation amount) is calculated and the date and time when the start of work in progress is stopped is set.

That is, in this feedforward control system, when there is a large change in the planned order quantity, the temporary bonding step (preceding step) 2 is performed to adjust the in-process quantity of the intermediate product in accordance with the planned order quantity. The date and time when the production of parts (intermediate products) should be started is being adjusted (production start adjustment processing). If the planned order quantity increases rapidly, the production of temporary bonded parts (intermediate products) can be started ahead of schedule to cope with the increase in the order quantity. In addition, when the planned order volume decreases sharply, especially when the order is expected to be discontinued,
Obtain the total amount of final products to be shipped by the time the order is discontinued, and stop the in-process product control of the intermediate products by the above-mentioned feedback control according to the current inventory amount of final products and intermediate products and the in-process amount of intermediate products. Therefore, the production of intermediate products is discontinued.

That is, in this production adjustment system, as shown in the concept of the control system in FIG.
And a feedback control system for optimizing and controlling the in-process circulation amount according to the order information and the in-process amount of the intermediate product, and the in-process inventory and the product according to the order information. With reference to the stock, a feedforward control system is provided which adjusts the production start date and time of the intermediate product, and further controls the production start itself to stop and optimize the in-process amount. In particular, under the condition that the in-process amount of the intermediate product is optimally controlled by the feedback control system, the production start date and time of the intermediate product is feedforward-controlled and the in-process termination is controlled according to the fluctuation of the planned order quantity. It is characterized by that.

The production adjustment of work-in-process products by the feed-forward control will be described in a little more detail. The production start adjustment processing means 14, for example, as shown in FIG. Order information that includes an order receipt that can be obtained about a month ago and an order confirmation that is notified three days ago is obtained [step S1], and it is determined whether or not there is a product discontinuation of the order [step S
2]. By the way, the discontinuation of product orders occurs when the specifications of the wire harness become unnecessary or the specifications themselves are drastically changed due to model changes in the destination of the wire harness. If there is no product order discontinuation, the circulation amount control described below is executed [step S3], and if there is an order discontinuation, total amount control described below is executed [step S4].

In the above-mentioned circulation amount control, for each day of the product order scheduled period, for example, as shown in the schematic processing procedure of FIG. 4, a sufficient quantity of intermediate products can be produced as work-in-process products. It is executed by verifying whether or not to obtain. That is, as shown in FIG. 4, first, the number of products shipped on the focused day (focused day) is determined according to the order information [step S11], and the number of products in stock on the focused day is calculated and assigned to the number of shipped products [ Step S12]. The number of products in stock is the number of final products that are produced in the assembly process (post-process) 3 according to a predetermined product production plan and are stored as waiting for shipment. If the product inventory is allocated to the product shipment number, then the product shortage number is calculated by subtracting the product shipment number from the product inventory number [step S13]. If the number of products in stock exceeds the number of products shipped, that is, if there is no shortage, then
Record as [0]. Simultaneously with the calculation of the product shortage number, the stock number of the final product left after the allocation of the product is obtained [step S14].

Thereafter, the number of product shortages obtained as described above is checked to determine whether or not the product inventory is short [step S15]. If the product inventory has a margin, that is, if there is no shortage, the day of interest is updated to the next day [step S16], and the processing procedure from step S11 described above is repeatedly executed. However, when the product inventory is insufficient [step S15], the inventory amount of the work-in-progress on the target day is checked, and the work-in-process is allocated to the number of product shortages [step S17]. The stock quantity of this work-in-progress is determined by a temporary production process (pre-process) 2 according to a predetermined product production plan.
It is the number of intermediate products that are produced before and used in the assembly process (post-process) 3. Then, if the in-process inventory is allocated to the number of products in short supply, the number of in-process products is calculated by subtracting the number of in-process products from the number of in-process inventory [step S18]. Even in this case, when the number of stocks in process exceeds the number of product shortages, that is, when the shortage does not occur, the number of shortages of work in process is recorded as [0]. Simultaneously with the calculation of the product shortage quantity, the assigned quantity is subtracted from the work-in-process inventory quantity to calculate the remaining work-in-process inventory quantity [step S19].

Then, it is determined whether or not there is a shortage of work-in-process based on the number of work-in-process insufficiencies or the quantity of work-in-process inventory [step S20]. Then, when the in-process inventory has a margin, that is, when there is no shortage, the above-mentioned day of interest is updated to the next day [step S16], and the processing procedure from step S11 described above is repeatedly executed. On the other hand, when a shortage occurs, the day when the shortage occurs, that is, the shortage of the work-in-process that is insufficient is obtained [step S21].

After that, in order to prevent the shortage of the work-in-progress, it is sufficient to prepare a large number of work-in-process. Therefore, the work-in-process is traced back by the amount of the lead time required for producing the product. In order to set the production start date, the recommended delivery date is set [step S22]. That is, the recommended finish time is set by tracing back the day by the lead time from the day when the in-process inventory runs short. Then, the production start date is feedforward controlled by adjusting the issuing time of the picture mark 1a for the cutting pressure / spline process (preparation process) 1 according to this recommended completion time.

More specifically, as shown in FIG. 6 as an example of the management table used in the production start adjustment process, the daily shipment number a of the product obtained according to the order information.
On the other hand, the above-described production start adjustment processing shown in FIG. 4 determines the product inventory quantity b, the product shortage quantity c, the work-in-process inventory quantity d, and the work-in-process shortage quantity e, respectively. In this example, the number of products shipped as of August 24, a
Is [12] while the product inventory quantity b of that day is [15], the product shortage quantity c of that day is obtained as [0] by the processing of step S23 described above. Further, by the process of step S24 described above, the product inventory quantity b after the product allocation on that day is obtained as [3], and is given as the product inventory quantity b of the next day.

And on the next day, August 25,
From the order information, the product shipment number a on that day is obtained as [4]. Then, since the product inventory quantity b is [3], the product shortage quantity c is obtained as [1], and the product inventory quantity b after product allocation is obtained as [-1]. At this time, there was a shortage of products. The in-process inventory is allocated to the product shortage number c as shown in step S27 described above. By the way, the in-process inventory amount d on this day
Is [50] in this example, so only one of the in-process inventory will be devoted to product shortage. Then, by the process of step S28 described above, the shortage amount f of work-in-process is obtained as [0], and the work-in-process inventory amount e after the work-in-process allocation is obtained as [49] by the process of step S29, and the work-in-process inventory amount of the next day. Given as.

When such processing is sequentially executed excluding preset holidays, in this example, the product shortage number d is obtained as [16] at the time of August 31, and this product shortage is obtained. Since the number of in-process inventory e that can be allocated to the number d is [3], the allocation of in-process products itself becomes insufficient. And the shortage f is [1
3] will be required.

Then, when a shortage of work-in-progress occurs, the completion date g of the work-in-process is calculated for managing the cut-off date for starting the production of the work-in-process [step S21], and the production of the work-in-process is started ahead of schedule. In order to do so, the recommended delivery date h of the intermediate product is set by tracing back the management date by a predetermined lead time [step S22]. Then, the production start date of the wire components in the cutting pressure / spline process (preparation process) 1 necessary for manufacturing the intermediate product (work-in-process product) is adjusted according to the recommended production period h.

Thus, as described above, the production start date and time (finishing date) of the intermediate product (work-in-process) according to the product order information.
As a result, according to the system equipped with the system that adjusts the production start date of the wire parts by feedforward control, in the state where the work-in-process quantity is optimized and adjusted by the above-mentioned feedback control, a sudden change in the order quantity It is possible to make a production plan without causing a product shortage. In particular, it becomes possible to predict shortages of materials in response to a large increase in orders, and to produce intermediate products that are produced in advance as work-in-progress by predicting surpluses in response to a sharp decrease in orders. It is possible to properly control the start time.

In particular, when the product inventory quantity is allocated to the product shipment quantity obtained from the order information, and the product inventory is insufficient, the in-process inventory is allocated to the product shortage, so that the number of the in-process goods that is truly short. Since the in-process amount is adjusted to obtain the value, it is possible to adjust the in-process amount according to the fluctuation of the order volume while maintaining an appropriate in-process amount of the intermediate product. Therefore, while dealing with a large change in the order quantity, a practically great effect can be obtained such that the quantity of work in process can be optimized and the production management that satisfies the order request can be performed.

On the other hand, in the above-mentioned total amount control, as shown in the schematic processing procedure in FIG. 6, the number of products shipped on each day (every day) until the deadline when the product order is discontinued is obtained, The total quantity of these product shipments is calculated [step S31]. Then, the stock quantity of the final product on the reference date (focusing day) for judging the suitability of the in-process quantity of the intermediate product is obtained, and this product stock quantity is allocated to the product shipment quantity (total quantity) [step S32]. Next, the number of product stocks left after the allocation of product stocks is obtained, and it is determined whether the product stocks are excessive [step S33]. If the product inventory is excessive, it is not necessary to produce the intermediate product as a work-in-progress any more, so the above-mentioned day of interest is obtained as the date on which the start of the work-in-process of the intermediate product should be stopped [step S4
0].

On the other hand, when the product inventory is insufficient with respect to the total number of product shipments [step S33], the temporary binding process (previous process) ) 2 and the stock quantity of work-in-process products in the standby state before being taken up by the assembly process (post-process) 3 is allocated [step S34]. Then, the number of in-process inventory remaining after the allocation of the in-process inventory is obtained, and it is determined whether or not the in-process inventory is excessive [step S35]. If the inventory of work in process is excessive, it is not necessary to produce the intermediate product as a work in progress any more. It is requested as a date to be stopped [step S40].

On the other hand, as described above, if the total number of product shipments and the number of product in-process stocks are all allocated to each other, but the total number of product shipments cannot be satisfied, that is, the number of in-process product stocks is insufficient. In the case of [Step S35], the in-process products being produced in the cutting pressure / spline process (preparation process) 1 and the temporary bonding process (previous process) 2 with respect to the number of product shipments for which these allocations could not be made. Is allocated (step S36). Then, the number of in-process intermediate products left after the allocation of the in-process circulation amount is obtained, and it is determined whether or not the number of in-process intermediate products (circulation amount) is excessive [step S37]. If the amount of work-in-process circulation is excessive, it is not necessary to produce the intermediate product as a work-in-process in this case as well. S40].

However, even after the allocation of the in-process circulation amount, if all of the above product shipment total numbers cannot be satisfied, that is, if the in-process circulation amount is also insufficient [step S37], the above-mentioned product shipment total number is reached. From the product shipment quantity on the day of interest [step S3
8]. Then, the day of interest is updated to the next day [step S3
9], the number of products obtained by subtracting the number of products shipped is set as a new total number of products shipped, and the processing procedure from step S32 described above is repeatedly executed.

According to the total quantity control executed when the product order discontinuation is detected in this way, the intermediate product in-process quantity is optimized while the intermediate product in-process quantity (work-in-process circulation quantity) is optimized by the feedback control described above. Since the date and time (production discontinuation date) to stop the start can be appropriately requested,
There is no need to overproduce intermediate products as work-in-progress. In particular, considering the number (quantity) of in-process intermediate products, it is possible to produce only the intermediate products required to produce the total number of product orders as in-process products prior to the confirmation of the order. The adjustment can be effectively performed without waste. Further, when the order is discontinued, it is possible to appropriately set the stop date for starting the work in process of the intermediate product.

When the start of the work in process of the intermediate product is stopped, the product production amount (lot size × number of lots) is preliminarily produced so that only a number (quantity) of the intermediate products corresponding to the number of ordered products are produced as the work in process. Needless to say, it is fine to adjust. When adjusting the production amount of the product, the production amount of the intermediate product may be gradually reduced each time the production of the intermediate product is started under feedback control, that is, each time the above-mentioned picture mark 1a is issued, or at the end. The production amount of the picture mark 1a may be adjusted at the time of issuance.

The present invention is not only applicable to a wire harness production line, but can be widely applied to various product production lines that require the production of intermediate products as work-in-progress. In addition, it is possible to change the lot size in producing the intermediate product as needed, and it is possible to control the in-process amount in a very fine manner. In addition, when adjusting the production start date of the intermediate product, it goes without saying that a predetermined number of extra days may be allowed. Further, it goes without saying that various forms can be adopted for the method of managing the production start date of the intermediate product and the method of managing the in-process amount. In addition, the present invention can be modified in various ways without departing from the scope of the invention.

[0045]

As described above, according to the present invention, the work-in-process quantity of the intermediate product is feedback-controlled and optimized in accordance with the expected order quantity, and when the order schedule is discontinued, the product inventory quantity is reduced. Since the start date and time of the in-process start of the intermediate product are determined by the feedforward control according to the in-process inventory amount and the in-process inventory amount, the in-process amount of the intermediate product can be easily and appropriately optimized according to the order volume of the final product. A great effect is practically exhibited.

[Brief description of drawings]

FIG. 1 is a diagram showing an overall schematic configuration of a production line in which a production adjustment system according to an embodiment of the present invention is incorporated.

FIG. 2 is a diagram showing a concept of a control system incorporated in the production line shown in FIG.

FIG. 3 is a diagram showing a schematic feedforward control function included in a production start adjustment process and a selection procedure thereof in the production adjustment system shown in FIG. 1.

FIG. 4 is a diagram showing a schematic processing procedure of circulation amount control in the production start adjustment processing shown in FIG.

FIG. 5 is a diagram showing an example of a management table for explaining a specific example of production start adjustment processing by circulation amount control.

FIG. 6 is a diagram showing a schematic processing procedure of total amount control in the production start adjustment processing shown in FIG.

[Explanation of symbols]

1 Cutting pressure / splice process (preparation process) 2 Temporary binding process (previous process) 3 Assembly process (post process) 11 In-process circulation amount control means 12 In-process setting amount setting means 13 In-process circulation amount operation unit (feedback control system) 14 Production start adjusting means (feedforward control system)

Claims (7)

[Claims] 1. A final product in a production line comprising a pre-process for producing an intermediate product which is a part of the final product as an in-process product and a post-process for producing the final product by using the intermediate product in response to an order. Is a system for adjusting the production amount of, the in-process amount detection means for obtaining the in-process amount of the intermediate product in the preceding process from the production required time of the intermediate product in the preceding process and the product production amount thereof, and the stock amount of the final product And inventory control means for respectively determining the inventory quantity of the intermediate product, and an in-process quantity control means for appropriately controlling the in-process quantity of the intermediate product in the preceding process according to the planned order quantity of the final product, and interruption of the order for the final product. When it is expected, the production start adjusting means for stopping the production start of the intermediate product according to the stock amount of each of the final product and the intermediate product and the in-process amount of the intermediate product in the preceding process. Production adjustment system, characterized by comprising a. 2. The in-process amount control means sets an in-process amount of an intermediate product in the preceding process as an in-process appropriate amount in accordance with an expected order amount of a final product, and the in-process amount detecting means. The production adjustment system according to claim 1, further comprising: a work-in-process circulation amount control means for adjusting the production amount of the intermediate product in the preceding step according to the work-in-process amount of the intermediate product and the appropriate in-process amount. 3. The production start adjusting means finds the total quantity of final products to be shipped before the order is discontinued, and allocates the stock quantity of each of the final products and intermediate products to the total quantity to find the shortfall. The production adjustment system according to claim 1, comprising means and means for controlling continuation / stop of the production start of the intermediate product in accordance with the shortage amount and the amount of the intermediate product in process in the preceding process. 4. The production of the intermediate product in the preceding step,
The predetermined number of intermediate products is set as one lot and is performed on a lot-by-lot basis, and the work-in-process control means adjusts the product production amount by increasing or decreasing the number of lots and / or the lot size. Production adjustment system. 5. The pre-process includes a preparatory process of manufacturing a plurality of types of parts necessary for production of an intermediate product, and the work-in-progress control means produces a plurality of kinds of parts in the preparatory process in accordance with an appropriate amount of a work-in-progress. The production adjustment system according to claim 1, wherein a production system for adjusting the quantities is started, and the production quantity of the intermediate product is controlled in accordance with the production quantities of the plurality of types of parts in this preparation step. 6. The post-process in the production line is for producing a wire harness as a final product, and the pre-process for producing an intermediate product as a work-in-progress is performed for each predetermined unit in the wire harness. The production adjustment system according to claim 1, wherein a plurality of wire components forming the unit are bundled, and a connector is attached to the end portions of these wire components to produce a temporary wire connection material. 7. The pre-process includes a preparatory process of previously producing a wire component necessary for producing a temporary wire material, wherein the production start adjusting means is in accordance with a date and time when the production of the temporary wire material should be stopped. The production adjustment system according to claim 6, which adjusts the date and time when the production of the line parts is stopped in the preparation step.