JP2003233406A - Collectively centralized storage method for semi-finished product of spare sheet-metal part - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To store spare sheet-metal parts for enabling reductions in storage costs. <P>SOLUTION: Before a sub-compression step of sheet-metal parts, press-finished products 6 are treated with preservative coating to convert into coated semi-finished products 9. While coating weld parts of the semi-finished product 9, the weld parts are left over as not-coated parts by masking with masking materials, a plurality of pieces of the semi-finished products 9 which have already coated are overlaid to be collectively packaged as assembly packaging 10 for collective storage and the semi-finished products 9 are stored at each packaging unit of the assembly packaging 10. Timing for performing of the collective storage should be the time when a predicted demand count reaches a predetermined value, for example, when a volume of molds matches with the storage volume of the whole semi-finished products 9 to be stored. From then on, the whole amount of the half-finished products which will be predicted in demand are produced collectively to store in stock and molds will be scrapped. The stored semi-finished products 9 are supplied gradually as finished products 6 by un-packaging and by performing necessary additional processing in response to demands. <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 an advantageous collective centralized storage method for stock sheet metal parts, such as repair sheet metal parts for automobiles, which are obliged to be stored for a long period of time.

[0002]

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

The one shown in the upper stage A of FIG. 1 is a conventional storage production method for a rear panel corresponding to a rear outer plate of an automobile as an example of this kind of repair sheet metal part. Each of the finished product's rear floor panels is individually packed into a finished product package 1 for sale,
For example, three of them are piled up one by one and housed in each compartment of the rack 2 for storage. In the case of sheet metal parts for automobile repair such as a rear panel, the vertical (Y), horizontal (X), and height (H) dimensions of the finished package 1 for sale are relatively large. It is obligatory to supply it while adjusting the inventory based on empirical demand forecast, and to keep it for a predetermined period and supply it to the purchaser even after the manufacture of the vehicle of the main body is finished.

FIG. 7 shows each step of manufacturing to storing a sheet metal part in this conventional example. First, an original sheet 3 is prepared (step (1)), and this is drawn into a predetermined shape to obtain a draw-formed product 4. Formed (step (2)), and further trimmed by cutting unnecessary portions and the like to obtain a trimmed product 5 (step (3)),
Subsequently, this is bent or bent or pierced to form a hole at a predetermined position to obtain a pressed product 6 (step (4)).

The pressing step is completed through these steps (1) to (4). It should be noted that the unfinished pressing in the steps (2) and (3) which are the pre-pressing steps and the step (4) which is the post-pressing step is a half-pressed product, and when the pressing step is completed through these steps (1) to (4) Pressed product 6 is obtained.

[0006] Further, the sub-compressed product 6 is formed by sub-compiling the press-finished product 6 by assembling and integrating other components such as nuts and other child parts (step (5)). , And then paint to obtain the finished product 8 (process
(6)), and packing them one by one to form the finished product packing form 1 (step (7)), and the process ends. These sheet metal parts are produced in small lots according to the stock situation, and are supplied to purchase applicants while adjusting the stock.

[0007]

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

In addition, in order to supply for a long period of time by such intermittent production, it is necessary to keep the mold for the entire period, which results in mold storage costs, rust prevention costs, maintenance costs, etc. This also increases the cost of inventory storage. Moreover, if the sheet metal parts are large, they will be limited to large-scale factories that can own large molds for manufacturing them, so the manufacturing location will be limited, and small lots will be manufactured in relatively small factories. It is difficult to take such agile response. In addition, it is difficult to deal flexibly when producing derivative types with different fine parts such as adding child parts or adding holes. Furthermore, when the production of sheet metal parts is started from an order, a lead time of, for example, about 100 days before supply is required.

The present applicant has already proposed a method for collectively storing and producing semi-finished products under a predetermined condition in order to overcome such problems (Japanese Patent Application No. 2001-233771).
According to this method, all of the demand-predicted products after a predetermined time are collectively produced as semi-finished products in an unpainted state, and a predetermined number of the products are hermetically sealed with a rust preventive sheet and then stored. However, since the inventory storage in the present invention is premised on long-term storage of several years, more reliable rust prevention treatment is desired. Therefore, the present invention is the inventory of repair sheet metal parts that enables more reliable rust prevention treatment. The purpose is to provide a storage method.

[0010]

In order to solve the above-mentioned problems, the invention relating to the method of centralized batch storage of repair sheet metal parts in the present application is manufactured from a plate-shaped member through steps of pressing, welding, assembling and painting. In the method of storing the sheet metal parts as a repair inventory, all the sheet metal parts whose demand is predicted after a predetermined time are collectively produced and stored in a semi-finished product coated with rust prevention, and The feature is that the mold is discarded.

At this time, the semi-finished product may be a press-finished product after the pressing process, which has been subjected to rust-preventive coating, and the welding and assembly processes may be incomplete. Further, the welded portion of this semi-finished product may be masked to be subjected to the rust-preventive coating to form a non-painted portion, and the non-painted portion may be covered with a rust-preventive peeling member and stored.

[0012]

According to the invention of the present application, all of the demand-predicted quantities after a predetermined time are collectively manufactured as a repaired sheet metal part as a semi-finished product, and a plurality of these are packaged and stored as one unit. Therefore, the storage space can be significantly reduced. Also, because the molds are discarded at the same time, it is released from long-term storage of molds,
The cost increase due to this can be avoided. Inventory whose storage period has expired can be discarded in the state of semi-finished products, and the process of making finished products is omitted, so costs associated with disposal can be saved.

The semi-finished products stored in a batch are then subjected to additional processing according to demand to be finished products, and supplied in required quantities. At this time, it is possible to flexibly respond to demand even for derivative types with different minute parts such as adding child parts or adding holes. Moreover, the finished product can be obtained only by additionally processing the semi-finished product, so that the lead time from order receipt to supply can be shortened. In addition, since additional processing for semi-finished products is relatively simple, restrictions on the equipment owned by the subcontractor when subcontracting the additional processing are lessened, and the degree of freedom in selecting subcontractors is increased.

Further, the sheet metal parts in stock for repair are packaged and stored in a batch in a semi-finished product with anticorrosion coating.
The rust preventive performance can be further enhanced, and the rust preventive treatment can be more reliable. As a result, it is possible to sufficiently withstand long-term storage for several years.

If the semi-finished product is a press-finished product that has been subjected to anticorrosion coating and the welding and assembling processes have not been completed, the packaging should be unpacked a little during storage depending on the demand. A finished product can be easily obtained only by assembling and assembling the assembled parts by welding or the like.

Further, when the semi-finished product is rust-proof coated, if the mask is applied to the rust-proof coating and the rust-proof coating is applied, the weld remains as a non-painted part. By occasionally peeling off the rust-proof peeling member, the unpainted welded portion can be exposed and welded. For this reason, it is possible to prevent the occurrence of welding defects due to painting and perform reliable welding.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION A storage production method using a vehicle rear panel as a repair sheet metal part will be described below with reference to the drawings. As shown in FIG.
Bending and piercing are performed on the trimmed product 5 in the step (2, 3)) to obtain a pressed product 6 in the latter stage of the pressing (step (4)). The vertical (y) and horizontal (x) dimensions of the finished press product 6 are close to the XY in the finished product packaging 1.

Thereafter, the pressed finished product 6 is subjected to cation electrodeposition coating and surface coating which also serves as rust preventive coating is performed to obtain a painted semi-finished product 9 (step (8)). The coating conditions such as paint components and coating film should be set so that sufficient rust prevention performance can be obtained. The pre-painted semi-finished product 9 is in a stage before the sub-computing of assembling the pressed finished product 6 by welding the child parts and the like, and the rust-preventive coating is performed at this stage. Masking the welded part of the semi-finished product in advance for anti-corrosion coating, then anti-corrosion coating (details will be described later) and stacking the coated products (process
(9) Further, this is packed in the collective package 10 for collective storage (step (10)).

The anticorrosion coating may be for finishing the final surface of the product or for pretreatment as a base. Although the final painting is done by coloring according to the demand forecast, the total number can be a single color (including transparent) for the base. However, the painting method is
Not only the cationic electrodeposition coating but also various well-known coating methods having good rust prevention performance can be applied.

It should be noted that the painted semi-finished product 9 stored in batch
Is a subcomp product 7 in small quantities according to the demand trend thereafter.
(Step 5). In this process, first, the packaging is unpacked to separate the painted semi-finished products 9, the masking material is removed from each to expose the non-painted parts, and the child parts are welded here to assemble the component parts. Unify.

After that, of the non-painted portion, the portion exposed from the attached child component and, if necessary, the component parts such as the child component are replenished and coated by an appropriate method such as brush coating, and if necessary,
Finished products will be processed by additional processing such as adding child parts and adding holes to support derivative types with different fine parts. These finished products are individually packaged and stored as finished product packaging 1, and are shipped and supplied in required quantities (process
(7)).

The lower part of FIG. 1 shows the hard surface in the storage of the painted semi-finished product 9. The collective package 10 for collective storage is stored in one package in one section of the rack 2, and the rack 2 as a whole is about the same size as the conventional one shown in the upper stage. Therefore, in the conventional case where three finished product packages 1 are stacked and accommodated in one division, the height h of the collective package 10 for collective storage is three times as high as the finished product package 1 (3H). To some extent,
This means that one collective storage package 10 for collective storage can be accommodated in one section of the rack 2 just.

That is, the dimensions x, y, h of the collective package 10 for collective storage are set to be approximately the same as the dimensions X, Y, 3H of the package 1 for finished product. The predetermined number of the painted semi-finished products 9 constituting 10 is set so as to be about 3H when stacked. As a result, one package 10 for collective storage is provided for each partition of the rack 2.
The number of painted semi-finished products 9 included in
Compared to the case of storing three finished products one by one in a package (that is, three finished products), the storage amount is significantly increased, and for example, about 3 to 5 times can be stored compared to the conventional example. become.

FIG. 3 shows an example of packing when the painted semi-finished products 9 are stored in a lump, and the painted semi-finished products 9 are, for example, 5 to 5.
10 pieces are piled up and a tear preventing tool 11 made of a known appropriate cushioning material such as a foam material is applied to the corner portion, and the whole is wrapped with a packaging sheet 12 made of an appropriate material such as vinyl so that the periphery is surrounded. Enclosed by a frame 13 of wire rods, a package 10 for collective storage in one package is provided.

The collective package 10 for collective storage is a unit of a transport mode that can be loaded and unloaded by a forklift or the like, and the frame 13 is provided with a strength to withstand such transport. If the packaging sheet 12 is a rust preventive sheet having excellent rust preventive properties, the rust preventive performance during storage can be further enhanced.

FIG. 4 is a diagram for explaining the handling of the welded portion during painting. A in the figure shows the state immediately before painting, around the bolt through hole 14 in a part of the finished press product 6, such as a nut. The welded portion 15, which is a place where the components of (1) are attached by welding, is covered with a masking material 16. Masking material 16
Is composed of an adhesive tape or the like, and is detachably covered and attached to the welded portion by adhesion, and can be easily peeled off later. In the case of the present embodiment, a material that is in good contact with the welded portion in a liquid-tight manner for a long period of time and has a good rust preventive property is selected. If it is covered with this masking material 16 and anticorrosion coating is applied, the welded part 15
Becomes a masked non-painted portion, and the entire surface of the press-finished product can be rust-proof coated by the coating film and the masking material 16.

FIG. 3B shows the welding step after painting, in which the masking material 16 is peeled off from the semifinished product 9 which has been painted, and the welded portion 1 is removed.
5 is exposed as a non-painted portion, and the nut 17 which is a child component is overlapped and welded there. After that, the unpainted portion 15a of the welded portion which is exposed without being completely covered by the nut 17 is painted and painted. At this time, if necessary, the nut 17 itself is also painted.

The child parts such as the coating portion 15, the masking material 16 and the nut 17 are merely examples, and various shapes and the like are possible. Also, other components other than the nut are properly attached and assembled as necessary. At this time, if necessary, the same masking process and additional coating process as for the welded portion 15 of the nut 17 can be performed.

The masking material 16 corresponds to the anticorrosive peeling member of the present invention and is continuously used from masking at the time of coating to long-term centralized storage. However, the rust preventive peeling member should be separated from the masking material 16, the masking material 16 should be peeled off after the rust preventive coating, and another non-corrosive peeling member having excellent rust preventive performance should be attached and covered on the non-coated portion thereafter. You may This makes it easier to identify the anticorrosion peeling member.

FIG. 5 shows a method for testing the anticorrosion performance of the painted semifinished product 9 by anticorrosion coating and anticorrosion peeling members. As for the rust prevention performance of the painted semi-finished product 9, it is necessary to exhibit a predetermined rust-proof property so that the semi-finished product, which is the content, will not rust over a long period of time. This rust preventive performance is judged by a constant temperature and humidity tank test with a predetermined cycle of summer and winter. In this test, the summer-winter day cycle is repeated a predetermined number of times, for example 1
Assuming 0 cycles / year, this is 5-10
If it does not generate rust after repeating the process for a year, it passes.

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

FIG. 6 is a diagram for showing the timing setting of this batch storage, and the curve is a demand curve showing the demanded number of repair sheet metal parts expected to be required in a certain period (year, month, etc.). is there. The horizontal axis is the period and the vertical axis is the forecast demand quantity and volume of the repair sheet metal parts. The demand curve rises after the car is released and reaches the peak C in a predetermined period. After that, it begins to decline gently.

This demand curve is determined based on an empirical rule, and the peak C is almost the time when the production of automobiles is stopped.
Up to peak C is the current production period of automobiles,
Repair parts will also be continuously produced at automobile production plants.
After peak C, the car becomes an old model, continuous production of repair parts at the car production plant is stopped, and small lots are produced intermittently while adjusting the inventory while considering the demand forecast after that, and further concentrated all at once. Production and storage takes place. Of the demand curves, the solid line shows medium demand and the broken line shows small demand.

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

The standard storage amount line D is set as a line in which the volume of the collective inventory storage amount at the point E coincides with the volume of the mold, and corresponds to the predetermined set value in the present invention. In addition, the bulk inventory storage amount is on the demand curve at point E.
It is the quantity that is integrated up to the inventory deadline thereafter, and is the total quantity that is predicted after that, with the point E at the predetermined time point.

When the solid demand curve intersects the standard storage amount lines D and E, the point E is set to a predetermined set value, and the expected total amount to be stored thereafter is manufactured in the state of the semi-finished product and then the mold is manufactured. , And shift to batch storage of semi-finished products,
Then keep it for a specified period. In this respect, it is clearly different from the conventional method in which a small lot production is intermittently continued until the end. Point G is the supply period of parts, and there is no special meaning at this point in the die storage in this embodiment, but conventionally it is necessary to continue to hold the die until the predetermined supply period from this point. It was

Thus, the value of point E, which is the predetermined set value in the expected number of demands, becomes the value when the package volume of the coated semi-finished product 9 to be stored at once and the volume of the mold match. Therefore, even if the painted semi-finished product 9 is stored for a predetermined long period of time thereafter, it is possible to make up for the storage space by discarding the mold, so that the storage space is the smallest and the repair sheet metal for a long period of time. Advantageous storage of parts.

As shown by the broken line, in the case of a product having a demand curve with a small demand, if it coincides with the standard storage amount line D at a considerably early time, for example, at the time of peak F, then at the time F, the It will be moved to bulk storage and the second half finished products will be stored for a predetermined period.

Next, the operation of this embodiment will be described. When the expected demand quantity reaches the predetermined set value D as described above, the repaired sheet metal parts are collectively manufactured as the painted semi-finished product 9, and a plurality of these are made into one unit to form the collective package 10 for collective storage. Package and store. Therefore, the storage space can be significantly reduced. Further, since the molds are discarded at the same time, the molds are released from long-term storage, and the cost increase due to this is avoided. Inventory that has expired can be discarded as a semi-finished product, and the process of making it into a finished product is omitted.
The costs associated with disposal can be saved.

The coated semi-finished products 9 stored in a batch are then unpacked according to demand, and gradually supplied to the purchasers as finished products with additional processing. At this time, it is possible to flexibly respond to demand even for derivative types with different minute parts by partially changing such as adding special child parts or adding holes according to the derivative specifications. Furthermore, the finished product can be obtained by simply performing additional processing on the semi-finished product, so that the lead time from order receipt to supply can be shortened. Since additional processing for semi-finished products is relatively simple, restrictions on the equipment owned by the subcontractor when outsourcing the additional processing are lessened, and the degree of freedom in selecting subcontractors is increased.

In addition, in the step (10), component parts such as child parts to be assembled by future welding or the like can be integrally stored by tying together. By doing this, it is not necessary to store these other parts separately from the pressed product, and it is possible to avoid inconvenient situations such as lack of components when in use, which is advantageous for storage when there are many component parts. Become.

Further, the painted semi-finished product 9 packed is a semi-finished product before sub-compression and is not bulky because other parts are not assembled by welding or the like. Thinner than, for example,
The packing height (thickness) is about 1/4. Conversely,
In the case of the same packing volume, it is possible to stack more sheets than the sub-comp product 7.

Moreover, since the painted semi-finished product 9 is rust-proof coated with the rust-proof coating and the masking material 16, the rust-proof performance can be further enhanced as compared with the case where the rust-proof sheet is packed and stored. It is a more reliable anti-rust treatment. as a result,
It can withstand long-term storage for several years.

In addition, since the masking material 16 is used as an anticorrosion peeling member and can be continuously used in common for coating and for long-term anticorrosion storage of the welded portion 15, the number of parts used and the number of coating and anticorrosion treatment steps can be reduced. . However, an anticorrosion peeling member may be prepared separately from the masking material 16. In this case, since the anticorrosion peeling member is attached after painting, it is possible to make it different from the coating color to make it stand out. There is.

Further, the welded portion 15 of the painted semi-finished product 9
Is masked with a masking material 16 for anti-rust coating, so that the welded portion 15 remains as a non-coated portion. Therefore, if the masking material 16 is removed at the time of subcomp, the unpainted welded portion 15
The nut 17 can be welded by exposing it. For this reason, it is possible to prevent the occurrence of welding defects due to painting and perform reliable welding.

It should be noted that the semi-finished product in stock is an incomplete sub-compact obtained by assembling and integrating some of the constituent parts of the press-finished product, the press-finished product 6 or the press-finished product which are in the middle of the pressing process. Any of the items may be used. However, in these cases, it is preferable that the product rust-preventive coating on the way of pressing is non-final such as for undercoating.

Among the above-mentioned products in the middle of pressing, as long as they are in the incompletely pressed state, they may be trimmed products 5, or various stages such as draw, vent or piercing. In the case of 1, since the volume per piece is the minimum, the storage space can be minimized.

In the case of the finished press product 6 or the incomplete sub-comp product, the volume is larger than that of the trimmed product 5, but since the process requiring a large press machine is completed, the working place is not limited thereafter and the operation is performed. Processing becomes possible. The size of the press machine changes before and after trimming even in the middle of pressing, so a smaller general-purpose machine can be used for the vent and piercing after trimming.

In the case of an incomplete sub-comp product, the volume is the largest, but since some of the components are integrated, some of these assembly parts (including the mold in some cases).
This eliminates the need for separate inventory, which is advantageous for parts management and inventory storage.

[Brief description of drawings]

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

FIG. 2 is a diagram showing a manufacturing process to a packing process.

[Figure 3] Diagram showing the packing method

FIG. 4 is a diagram showing masking.

FIG. 5 is a diagram showing a rust prevention test method.

FIG. 6 is a diagram showing the timing of determining the set demand quantity.

FIG. 7 is a diagram showing a conventional manufacturing-packing process.

[Explanation of symbols]

1: Complete packaging for sale, 2: Rack, 3: Original sheet, 4: Draw molded product, 5: Trimmed product, 6: Pressed product, 7: Subcomp product, 9: Painted semi-finished product, 1
0: Collective package for collective storage, 11: Tear prevention tool, 1
2: Anticorrosion sheet, 13: Frame, 15: Welded portion, 16: Masking material, 17: Nut (child component welded as a component)

Claims (3)

[Claims] 1. A method of storing sheet metal parts manufactured from a plate-shaped member through press, welding, assembling, and painting processes as a stock for repair, in which a total amount of the sheet metal parts predicted to be demanded after a predetermined time is calculated. , Centralized storage method for batch-finished semi-finished products of repair sheet metal parts, in which a plurality of semi-finished products with anticorrosion coating are produced and stored, and the molds are discarded. 2. The semi-finished product is a press-finished product that has undergone a pressing process and is subjected to rust-preventive coating, and the welding and assembly processes have not been completed. Collective storage method for semi-finished sheet metal parts for repair. 3. The semi-finished product is characterized in that the welded portion is masked and the anticorrosive coating is applied to form an unpainted portion, and the nonpainted portion is covered with an anticorrosive peeling member and stored. A method for collectively storing semi-finished products of repair sheet metal parts described in item 2.