JP2006202214A - Production management system, production management method, production management program, and recording medium storing production management program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manage not only production but also vehicle uses and a production cycle in a production management system for a production method that feeds workpieces between processes by means of vehicles. <P>SOLUTION: When workpieces are loaded on the workpiece vehicle 1, loaded workpiece information and workpiece vehicle information are given to the workpiece vehicle 1. At a workpiece destination, the workpiece vehicle information is read by a management system 10, which matches it against information stored in advance in the management system for confirmation according to operation rules. If there is an operation rule violation, a warning device 20 gives a warning. If not, the loaded workpiece information is read by the management system 10, which creates a production result according to the information and displays the production result on a display device 30, so that the workpiece vehicle use and production cycle can also be managed in addition to production management. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a production management system, a production management method, a production management program, and a recording medium storing a production management program for managing workpieces conveyed between production processes, and in particular, a mode in which workpieces are conveyed by a carriage between production processes. The present invention relates to a production management system, a production management method, a production management program, and a recording medium storing the production management program.

  In a production method in which a workpiece is transported by a transport carriage from an arbitrary process to the next process, the processing speed of the workpiece may be different between the processes. In such a case, production is performed while holding a buffer between the processes. .

  In such production, workpieces that are mistakenly introduced from among workpieces temporarily held as buffers may be transported to the next process first, eliminating the need for workpieces that have been thrown in first. It may stay. In order to improve this, conventionally, “first-in first-out” management of transporting workpieces to the subsequent process in the order in which workpieces are loaded has been performed to prevent unwanted workpieces from staying. “First-in first-out” management is performed by assigning a number to the work conveyance carriage on which the work is mounted, and the worker conveys the work in the order of the number. In addition, in-process inventory and production progress are managed by checking the type and quantity of workpieces when conveying workpieces.

Further, depending on the production process, due to demands for labor saving of workpiece conveyance, workpiece conveyance between processes is completely automatically conveyed by an unmanned conveyance cart. When changing the workpiece delivery position in such a system, it is necessary to modify the control program of the automatic guided vehicle, which takes time and effort. Thus, in order to improve the convenience of work in changing the work transfer route, a work transfer method that can also be used for auxiliary work by a person has been proposed (for example, see Patent Document 1). According to this method, since the operator can manually release the connected state of the connected member transport carriages, the position of workpiece transfer can be easily changed.
JP-A-8-290710 (pages 4-5, 5-6)

  However, in the conventional production management method, even if unnecessary work retention and production progress can be managed, it has not been possible to easily manage production tact time. When managing the tact time, it was necessary to add hardware, and to secure personnel that expected management man-hours.

  Further, in the conventional production management method, even when the workpiece is managed, the workpiece conveyance cart is not managed, and it is impossible to grasp what purpose the workpiece conveyance cart is actually used for.

  In addition, when workpiece transfer between processes is automated, the workpiece transfer carriage is under the control of an automatic system for automation, but the connection state of the transfer carriage is manually released as in the prior art. If the transfer work is improved by this, the work transfer carriage to be released is not controlled by the automatic system, so it is difficult to grasp what purpose each work transfer carriage is actually used for. It was.

  The present invention has been made in view of these points. The purpose of the present invention is to perform accurate work-in-process inventory management between processes, work "first-in first-out" management, production progress management, and management of production efficiency. Production management system, production management method, and production management that can manage the tact time in each process and that can easily change the usage of the work conveyance cart while also managing the usage of the workpiece conveyance cart A recording medium storing a program and a production management program is provided.

In order to solve the above-mentioned problems, the production management system of the present invention is a production management system for transporting a workpiece using a carriage from an arbitrary process to the next process, and includes a workpiece conveyance carriage for conveying a workpiece, Consists of a management system for managing the carriage and workpiece, a warning device, and a display device,
The workpiece transfer carriage includes a carriage on which a workpiece is mounted, a mounted work information storage unit in which mounted work information of the mounted work mounted on the carriage is stored in a state where the management system can input and acquire the work, and A workpiece conveyance carriage information storage unit in which the given workpiece conveyance carriage information is stored in a state that can be input and acquired by the management system;
The management system includes an operation rule that defines the operation of the work carriage, a production result database, a management unit that manages a production plan that is a basis for creating the mounted work information, and an input that inputs the operation rule and the production plan. An information input acquisition unit for inputting and acquiring the mounted work information and the work transport carriage information by communicating with the mounted work information storage unit and the work transport cart information storage unit, and at least operation violation warning information or tact A processing unit that creates any one of the time excess warning information and calculates production progress information from the mounted work information and the production performance database,
The processing unit collates the work conveyance carriage information with the operation rule to determine an operation rule violation of the work conveyance carriage, and in the case of an operation rule violation, creates an operation violation warning information, or the production plan While measuring the time that the workpiece exists in the process, if the workpiece exceeds the takt time of the production plan, while creating the takt time exceeded warning information,
The warning device issues a warning based on the operation violation warning information or the tact time excess warning information, and the display device displays the production progress information.

  In a production method in which a workpiece is conveyed using a workpiece conveyance carriage from any process to the next process, the workpiece loading information of the workpiece mounted on the workpiece conveyance carriage and the workpiece conveyance carriage information of the workpiece conveyance carriage itself are the workpiece conveyance carriage. To be granted. On the other hand, in the management system, a production plan, which is a base for creating on-board work information, an operation rule for determining the operation of the work conveyance carriage, and a production result database indicating the production progress status are managed. Then, at the workpiece transfer destination, the management system reads the workpiece transfer carriage information given to the workpiece transfer carriage and compares it with the operation rules of the management system, and determines the violation of the operation of the workpiece transfer carriage. In the case of an operation violation, a warning is issued by the warning device, and if it is not an operation violation, the on-board work information attached to the work carriage is read and the production result database is updated, so that the current production progress status Is displayed on the display device. Further, the stay time of the work is measured by the processing unit, and when the work stay time exceeds a preset tact time, tact time excess warning information is created, and a warning is issued by the warning device.

  In other words, by adding work information to the work carriage when the work is transported, the work information will also move each time the work is transported, so the work inventory quantity and production work in progress quantity for each process Will be fully understood.

  Moreover, the workpiece conveyance cart itself is grasped by giving the workpiece conveyance cart information to the workpiece conveyance cart. For example, when the usage information is given to the workpiece conveyance carriage, the number of workpiece conveyance carriages can be managed for each usage.

  In addition, since the operation of the work conveyance carriage itself is managed based on the operation rules based on the work conveyance carriage information, a work conveyance error can be eliminated.

  In addition, the operation of the work transport cart is regulated based on the operation rules based on the work transport cart information, and these information can be rewritten, so only by changing the work transport cart information or the operation rules. The operation of the work conveyance cart can be easily changed without the need to change the program itself.

  In addition, the work staying time during the process is measured, and when a preset tact time is exceeded, a warning is issued to alert the worker. It is possible to prevent staying in a useless process.

  Moreover, the workpiece conveyance cart may be equipped with a cart information display unit that displays at least one of the mounted workpiece information and the workpiece conveyance cart information.

  By adopting such a configuration, it is possible to make the worker who conveys the workpiece conveyance carriage recognize the workpiece conveyance carriage information or the mounted workpiece information.

  Further, the mounted work information may be composed of at least one piece of information among the type of work to be mounted, the number, and the mounting time of the work.

  By setting it as such an information structure, a production performance can be managed for every kind of work. In addition, since the loading time and number of workpieces can be ascertained for each type of workpiece, the number of workpieces processed at an arbitrary time can be calculated, and the production efficiency between arbitrary processes can be managed.

  Moreover, you may comprise the workpiece conveyance trolley information from at least 1 information among a workpiece conveyance trolley number and the use number of a workpiece conveyance trolley.

  By using the workpiece conveyance carriage number, the workpiece conveyance order can be determined simply by comparing the numbers, so that the first-in first-out management of the workpiece conveyance carriage can be easily performed. In addition, the number of workpiece transfer carts used can be easily grasped.

  In addition, by assigning the use number of the work transfer carriage to the work transfer carriage, it is possible to manage the production of the work transfer carriage for each use. In addition, since the workpiece transfer cart is managed based on the operation rules with reference to the workpiece transfer cart information, the workpiece transfer cart can be brought under the operation rules for different uses only by changing the usage number of the workpiece transfer cart information. Can be put. That is, it is possible to easily change the usage of the work transport carriage without changing the management system program or the like.

  In addition, the management unit may have a function of generating the work transfer carriage number with a serial number by referring to the work transfer carriage information generated immediately before, and the work transfer carriage number may be a serial number. .

  By generating the workpiece transfer carriage number in this way, the workpiece transfer carriage can be easily managed. That is, by assigning the workpiece transfer carriage number with a serial number each time a workpiece is mounted, the transfer order of the workpiece transfer carriage is clarified, and the “first-in first-out” determination is simplified.

In order to solve the above-mentioned problems, the production management method of the present invention is a production management method for transporting a workpiece using a carriage from any process to the next process, and the workpiece is transported in any process. Mounted work information storage procedure for storing the mounted work information of the work to be mounted on the work transport carriage prepared in advance based on the production plan in the mounted work information storage section provided in the work transport carriage, Work transfer carriage information storage procedure for storing work transfer carriage information created in advance based on a production plan in a work transfer carriage information storage unit provided in the work transfer carriage;
In the next step, the workpiece conveyance carriage information acquisition procedure for acquiring the workpiece conveyance carriage information from the workpiece conveyance carriage information storage unit, the operation rule defining the operation rule of the workpiece conveyance carriage, and the workpiece conveyance carriage information are collated. A determination procedure for determining an operation rule violation, a warning procedure for issuing a warning with a warning device when the result of the determination is an operation rule violation, and the mounted work information when the determination result is not an operation rule violation A loading work information acquisition procedure obtained from a work information storage unit, and a display procedure for calculating production progress information from the loading work information and a production performance database stored in a management system, and displaying this on a display device. It is characterized by that.

  In the production management method having such a configuration, the same effect can be obtained by the same operation as the above-described production management system.

  Moreover, the workpiece conveyance cart may include a procedure for displaying at least one piece of information on the carriage information display unit among the mounted workpiece information and the workpiece conveyance cart information.

  Further, the mounted work information may be configured from at least one piece of information among the type of work to be mounted, the number, and the mounting time of the work.

  Moreover, you may comprise the workpiece conveyance trolley information from at least 1 information among a workpiece conveyance trolley number and the use number of a workpiece conveyance trolley.

  Moreover, before the workpiece conveyance cart information storing procedure, a procedure for generating the workpiece conveyance cart number sequentially by referring to the workpiece conveyance cart information generated immediately before may be provided.

Further, it is a production management method of a production method in which a work is conveyed using a carriage from an arbitrary process to the next process, and the work arrival time acquisition procedure for acquiring the arrival time of the work, and the work remains in the optional process. The work stay time acquisition procedure for measuring the work stay time that is
The tact time excess determination procedure for comparing the tact time stored in the production plan with the work stay time acquired in the work stay time acquisition procedure, and the work stay time exceeds the tact time in the tact time excess determination procedure. A tact time excess warning information creation procedure for creating a tact time excess warning information, a tact time excess warning information output procedure for outputting the tact time excess warning information created in the tact time excess warning information creation procedure, It is characterized by including.

  With such a configuration, when the workpiece transport carriage arrives at the process, the arrival time at which the workpiece arrives is acquired, the time that the workpiece stays at an arbitrary process is measured from the workpiece arrival time, and the workpiece stays at the process. Compare the stay time with the tact time set in advance in the production plan at predetermined time intervals or in real time, and issue a warning if the tact time is exceeded, thus managing the work tact time. Will be.

In order to solve the above-mentioned problems, the production management program of the present invention is a production management program for a production system that transports a workpiece from an arbitrary process to the next process using a carriage, and the workpiece is transported at an arbitrary process. Mounted work information storage step of storing in the mounted work information storage unit provided in the work transport carriage, the work information of the work to be mounted on the work transport cart prepared in advance based on the production plan, A workpiece conveyance carriage information storage step for storing workpiece conveyance carriage information created in advance based on a production plan in a workpiece conveyance carriage information storage unit provided in the workpiece conveyance carriage;
In the next step, a workpiece transfer carriage information acquisition step for acquiring the workpiece transfer carriage information from the workpiece transfer carriage information storage unit, an operation rule that defines an operation rule of the workpiece transfer carriage, and the workpiece transfer carriage information are collated. A determination step for determining an operation rule violation, a warning step for issuing a warning by a warning device when the result of the determination is an operation rule violation, and the mounting work information when the determination result is not an operation rule violation A mounted work information acquisition step acquired from a work information storage unit, and a display step of calculating production progress information from the mounted work information and a production performance database stored in a management system, and displaying this on a display device. It is characterized by that.

  Moreover, the workpiece conveyance cart may include a step of displaying at least one information of the mounted workpiece information and the workpiece conveyance cart information on the cart information display unit.

  Further, the mounted work information may be configured from at least one piece of information among the type of work to be mounted, the number, and the mounting time of the work.

  Moreover, you may comprise the workpiece conveyance trolley information from at least 1 information among a workpiece conveyance trolley number and the use number of a workpiece conveyance trolley.

  Moreover, before the workpiece conveyance cart information storing step, a step of generating the workpiece conveyance cart number sequentially by referring to the workpiece conveyance cart information generated immediately before may be provided.

  Further, a production management program for a production system that transports a workpiece using a carriage from an arbitrary process to the next process, the workpiece arrival time acquisition step for acquiring the arrival time of the workpiece, and the workpiece remains in the arbitrary process. A work stay time acquisition step for measuring a work stay time that is a certain time, a tact time stored in the production plan and a tact time excess determination step for comparing the work stay time acquired in the work stay time acquisition procedure, Created in the tact time excess warning information creation step for creating the tact time excess warning information and the tact time excess warning information creation step when the work stay time exceeds the tact time in the tact time excess determination procedure. A tact time excess warning information output step for outputting tact time excess warning information; Characterized in that it contains.

  In the production management program having such a configuration, the same effect can be obtained by the same operation as the above-described production management system.

  In order to solve the above problems, a recording medium storing the production management program of the present invention may be used.

  According to the present invention, in a production management system for a production system that transports a workpiece from an arbitrary process to the next process using a carriage, the workpiece conveyance carriage for conveying the workpiece, the workpiece loading information on the workpiece to be loaded, and the workpiece conveyance carriage By assigning individual workpiece carriage information and processing this information in the management system, management of the order in which workpieces are sent to production (first-in first-out management), accurate work-in-process inventory management between processes, and production progress It is possible to accurately manage the application management / operation status of the work conveyance cart. Further, it is possible to manage production efficiency and work tact time in each process without adding new equipment. Furthermore, it is possible to change the usage of the work conveyance carriage without taking time and effort such as changing the program itself, and also to manage the usage of the workpiece conveyance carriage whose usage has been changed.

  Embodiments of the present invention will be described below with reference to the drawings.

  The form of the production management system according to the present invention will be described with reference to FIGS.

  FIG. 1 is a system configuration diagram of a production management system according to an embodiment of the present invention. FIG. 2 is an overall configuration diagram of the workpiece transfer carriage according to the embodiment of the present invention. FIG. 3 is a schematic configuration diagram of the management system according to the embodiment of the present invention. FIG. 4 is an explanatory diagram showing an example of the mounted work information in the embodiment of the present invention. FIG. 5 is an explanatory diagram showing an example of the workpiece conveyance carriage information in the embodiment of the present invention. FIG. 6 is an explanatory diagram illustrating an example of information display of a cart information display unit provided in the work conveyance cart according to the embodiment of the present invention. FIG. 7 is an explanatory diagram showing an example of information stored in the usage storage database according to the embodiment of the present invention. FIG. 8 is an explanatory diagram showing an example of a production plan in the embodiment of the present invention. FIG. 9 is an explanatory diagram showing an example of a production performance database in the embodiment of the present invention. FIG. 10A is an explanatory diagram illustrating an example of a warning display for use violation in the embodiment of the present invention, and FIG. 10B is an explanatory diagram illustrating an example of a warning display for first-in first-out violation in the embodiment of the present invention. FIG. 10C is an explanatory diagram showing an example of a tact time warning display in the embodiment of the present invention. FIG. 11 is an explanatory diagram showing an example of the production progress display in the embodiment of the present invention.

  As shown in FIG. 1, the production management system includes a work carrier 1, a management system 10, a warning device 20, and a display device 30. Each component will be described in detail below.

  The workpiece conveyance carriage 1 will be described with reference to FIGS. 1 and 2. The workpiece conveyance carriage 1 includes a carriage 2 that loads and conveys a workpiece, a loaded workpiece information storage unit 3 that stores loaded workpiece information of the workpiece loaded on the carriage 2, and a workpiece conveyance carriage information that stores workpiece conveyance carriage information. It is comprised from the storage part 4 and the trolley | bogie information display part 5 which displays mounting workpiece | work information and workpiece conveyance trolley | bogie information.

  The cart 2 is a kind of wagon with a caster provided with a top plate and a shelf plate, and a work is mounted on the top plate.

  The mounted work information storage unit 3 has a function of storing the mounted work information of a work mounted on the work transport carriage 1 and a function of transmitting and receiving the mounted work information. That is, the mounted work information storage unit 3 receives and stores the mounted work information transmitted from the management system 10. Further, the mounted work information is transmitted to the management system 10 in response to a transmission request from the management system 10.

  As shown in FIG. 4, the mounted work information is composed of the type of work mounted on the work carriage 1, the number (number), and the time when the work is mounted. By managing the type and number of workpieces together with the conveyance of workpieces, the production performance can be grasped for each workpiece type each time conveyance is performed. In each arbitrary process, the process inventory can always be grasped for each type of workpiece from the number of workpieces transferred and carried in and the number of inventory workpieces. In addition, by managing the loading time together with the workpiece conveyance, the workpiece conveyance amount between arbitrary processes between arbitrary times can be grasped, so the processing quantity per unit time of the workpiece is calculated, and between each process The production efficiency of the workpiece can be grasped.

  The workpiece transfer carriage information storage unit 4 has a function of storing workpiece transfer carriage information given to each workpiece transfer carriage 1 and a function of transmitting and receiving workpiece transfer carriage information. In other words, the work transport cart information storage unit 4 receives and stores the work transport cart information transmitted from the management system 10. In addition, the work carriage information is transmitted to the management system 10 in response to a transmission request from the management system 10.

  As shown in FIG. 5, the workpiece conveyance carriage information is composed of a workpiece conveyance carriage usage number and a workpiece conveyance carriage number.

  The workpiece conveyance cart number is created according to a certain rule (for example, a serial number) from the start of production, and is given to the workpiece conveyance cart 1 in the order in which workpieces are mounted. By transferring the workpieces in the order of the workpiece transfer carriage numbers, first-in first-out management of the workpieces is realized, thereby preventing unnecessary stagnation of the workpieces.

  The work transfer carriage use number indicates the use of the work transfer carriage 1. For example, as shown in FIG. 7, 1 is numbered for the purpose of conveying the workpiece from the A process to the B process, and 2 is numbered for the purpose of conveying the work from the B process to the C process. Thereby, the workpiece conveyance error can be eliminated by checking the workpiece conveyance truck usage number at the workpiece conveyance destination and determining whether the number is compatible with the usage. Moreover, the usage of the workpiece conveyance carriage 1 can be changed by changing the workpiece conveyance carriage usage number assigned to the workpiece conveyance carriage 1.

  In addition, by managing the number of workpiece transfer carriages for each application using the workpiece transfer carriage application number, the number of workpiece transfer carriages can be adjusted according to the production plan for each application. Moreover, the number of workpieces conveyed by the workpiece conveyance cart 1 can be limited by limiting the number of workpiece conveyance carts 1 used for each application. As a result, the number of in-process inventory in the process can be limited (total amount regulation is performed).

  For example, as shown in FIG. 6, the cart information display unit 5 displays the type of workpiece, the number, the time when the workpiece is mounted, the workpiece conveyance carriage application number, and the workpiece conveyance cart number. Thereby, the worker can check the mounted work information and the work transport carriage information even during the work transport.

  Note that the mounted work information storage unit 3 and the work transport carriage information storage unit 4 are not separate recording media, and one storage medium is divided into two storage areas so that the mounted work information and the work transport cart information can be distinguished. May be stored. Moreover, you may implement | achieve the function which transmits / receives the mounting work information storage part 3 and the workpiece conveyance trolley information storage part 4 using a common apparatus.

  Next, the management system 10 will be described with reference to FIGS. 1 and 3. The management system 10 includes a management unit 11, an input unit 12, an information input acquisition unit 13, and a processing unit 14.

  The management unit 11 manages a production result database in which operation rules, production plans, and production results for each work are determined as a database. A production plan exists in each process, and based on this production plan, mounted workpiece transfer information of a workpiece mounted on the workpiece transfer cart 1 is created. The production result database is a database in which production results are accumulated for each work type based on the mounted work information acquired from the mounted work information storage unit 3 of the work conveyance carriage 1.

  Moreover, the management part 11 has a function which produces | generates the workpiece conveyance trolley information. Of the workpiece conveyance carriage information, the workpiece conveyance carriage usage number is determined in advance based on the production plan, and is input to the workpiece conveyance carriage in advance before the start of production. Of the workpiece conveyance carriage information, the workpiece conveyance truck number has a maximum value determined in advance for each type of workpiece or each use of the workpiece conveyance carriage based on a production plan. Further, before the work is mounted, it is generated by serial numbers with reference to the work carriage information generated last time.

  The operation rules include that the work transport cart 1 operates according to the use of the use storage database, that the work transport cart 1 operates in the order of the work transport cart number (or in the order of a certain rule), and a predetermined time in any process. It is set that the quantity of workpieces conveyed between them is greater than or equal to a predetermined quantity or within a predetermined quantity range. In addition to this, an operation rule may be set. For example, the operation rule may be set such that the workpiece conveyance is stopped when the workpiece inventory quantity in a predetermined process exceeds a predetermined quantity.

  For example, as shown in FIG. 7, the usage storage database is composed of a workpiece conveyance carriage usage number and usage. The use is defined as the interval between processes in which the work conveyance carriage 1 is used, for example, “used for conveyance from the A process to the B process”.

  For example, as shown in FIG. 8, the production plan includes a lot number, a type of work (type), a work amount that can be mounted on the work carriage 1 (the number of mounted carriages), a quantity of one lot of work (the number of lots), and each It consists of the tact time per car in the process. By setting the number of mounted carriages as an item, the transfer capability of the workpiece transfer carriage 1 can be grasped for each type of workpiece, so that production management can be performed based on the transfer of the workpiece transfer carriage 1 for each type of workpiece. It becomes possible. In addition, for each type of workpiece, the time required to process the number of mounted workpieces per carriage in each process, that is, the takt time is set in the production plan in advance, and the workpiece processing time is set as the takt time. The production progress can be managed by managing based on the above.

  As shown in FIG. 9, the production record database is composed of the type of work (type), the number of times workpiece loading information indicating the number of times the work has been transferred to an arbitrary process, and the production record for each model. The production performance for each model is calculated by multiplying the workpiece mounting information input count by the number of trucks described above.

  The input unit 12 inputs operation rules and production plans to the management unit 11.

  The information input acquisition unit 13 includes a mounted work information input unit 13a, a mounted work information acquisition unit 13b, a work transport cart information input unit 13c, and a work transport cart information acquisition unit 13d.

  The mounted work information input unit 13 a has a function of transmitting the mounted work information generated by the management unit to the mounted work information storage unit 3 provided in the work transport carriage 1.

  The mounted workpiece information acquisition unit 13 b has a function of acquiring the mounted workpiece information from the mounted workpiece information storage unit 3 provided in the workpiece transport carriage 1 and transmitting it to the management unit 11.

  The workpiece transfer carriage information input unit 13 c has a function of transmitting the workpiece transfer carriage information generated by the management unit to the workpiece transfer carriage information storage unit 4 included in the workpiece transfer carriage 1.

  The workpiece transfer carriage information acquisition unit 13 d has a function of acquiring the workpiece transfer carriage information from the workpiece transfer carriage information storage unit 4 included in the workpiece transfer carriage 1 and transmitting it to the management unit 11.

  The mounted work information input unit 13a and the work transfer carriage information input unit 13c can be realized as a single transmission device if information can be transmitted to the mounted work information storage unit 3 and the work transfer carriage information storage unit 4 in a distinguishable manner. May be. Moreover, you may implement | achieve the mounting workpiece | work information acquisition part 13b and the workpiece conveyance trolley | bogie information acquisition part 13d as one information acquisition apparatus.

  The processing unit 14 determines whether or not the conveyance of the work conveyance carriage 1 is correct based on the operation rule, and creates warning information when the operation rule is violated, and transmits the warning information to the warning device. Specifically, the use determination as to whether or not the workpiece is being conveyed based on the workpiece conveyance carriage application number assigned to the workpiece conveyance carriage 1, the workpiece is conveyed in the order of the workpiece conveyance carriage number assigned to the workpiece conveyance carriage 1. First-in first-out determination is made as to whether or not there is.

  The use determination is to check whether or not there is a violation in the use of the work transport carriage 1 by comparing the work transport carriage use number with the number of the use storage database stored in the management unit 11. In the case of use violation, this is treated as an operation rule violation, warning information (FIG. 10 (a)) for displaying appropriate transport destination data of the work is created and transmitted to the warning device 20. Thereby, the mistake of the conveyance destination of a workpiece | work can be eliminated. Specifically, in the use storage database, when the work transport carriage number is 1 and the corresponding use is “used for transport from process A to process B”, the work transport truck use number is 1. When a certain work transport carriage 1 is erroneously used for transporting a work from “A process to C process”, it is determined as a use violation in the transport process C process, and this information is transmitted to the warning device 20.

  The first-in first-out determination is performed by collating the workpiece conveyance carriage number of the workpiece conveyance carriage information acquired by the workpiece conveyance carriage information acquisition unit 13d with the workpiece conveyance carriage number of the workpiece conveyance carriage information acquired immediately before the workpiece conveyance carriage 1 Is determined according to the order. If there is a first-in first-out violation, this is handled as an operation rule violation, and warning information (FIG. 10 (b)) indicating the valid order of the work conveyance cart is transmitted to the warning device 20. As a result, first-in first-out management of workpieces is performed, and unnecessary stagnation of workpieces can be prevented.

  The processing unit 14 stores the time when the work input is acquired by the information input acquisition unit when the work is carried into the process, and measures the work stay time at which the work stays in the process from this time. The stay time and a tact time preset for each type of work in each process are compared at regular time intervals or in real time to determine whether the stay time does not exceed the tact time.

  If the work staying time exceeds a preset tact time based on the tact time excess determination, tact time excess warning information (FIG. 10 (c)) indicating that the work processing is delayed is displayed as a warning device. 20 to send. Thereby, the tact management of a workpiece | work can be performed in each process.

  Further, the processing unit 14 calculates the processing quantity per predetermined time for each type of work from the mounting time of the mounting work information acquired by the mounting work information acquisition unit 13b and the production performance after a predetermined time has passed. A production efficiency determination may be made to determine whether the processing quantity is greater than or equal to a predetermined quantity set in advance, or whether it is within a predetermined quantity range set in advance. As a result, when there is a violation of production efficiency, a warning is issued and the production efficiency can be managed for each type of work.

  Further, the processing unit 14 adds the mounted work information acquired by the mounted work information acquiring unit 13b to the production result database managed by the management unit 11, and newly creates a production result database (FIG. 9). As a result, the latest production progress is grasped each time the workpiece is conveyed. For example, as shown in FIG. 9, when the number of models A mounted on the work conveyance carriage 1 is 40, the production results of the model A when the model A is conveyed 10 times by the work conveyance carriage 1 in the A process. Is calculated as 400.

  Next, the warning device 20 will be described with reference to FIG.

  Based on the determination by the processing unit 14, the warning device 20 has a function of warning a use violation of the work conveyance carriage 1, a first-in first-out violation of the work conveyance carriage 1, a tact time violation, and the like. For example, in the case of violation of usage, as shown in FIG. 10 (a), an operation rule violation is displayed on the display of the warning device, and an appropriate work movement location is displayed. Further, in the case of a first-in first-out violation, an operation rule violation is displayed on the display of the warning device as shown in FIG. 10B, and an appropriate work conveyance carriage number is displayed. Also, in the case of a violation of the tact time excess, the tact time excess violation is displayed on the display of the warning device as shown in FIG. 10C to alert the operator. With such a display, it is possible to notify the operator of work mistakes and processing delays without delay, and production management is performed smoothly. This warning may be performed with a warning sound using a speaker without using a display.

  The warning device 20 is provided for each point of the workpiece conveyance destination. Therefore, even if an operator mistakenly conveys the workpiece, the workpiece conveyance carriage information given to the workpiece conveyance carriage 1 is read and a violation of the operation rules is made and a warning is issued. Can be transported.

  Next, the display device 30 will be described with reference to FIG.

  The display device 30 displays, for example, the production record among the production record databases created by the processing unit 14 of the management system 10 (FIG. 11). Since the display device 30 is provided for each point of the workpiece conveyance destination, the worker can grasp the production progress every time the workpiece is conveyed.

  The warning device 20 and the display device 30 may be shared by a single display, and an operation rule violation display, a tact time excess display, and a production record may be displayed simultaneously.

  In addition, the production management system according to the present invention may be constructed by using a device capable of reading and writing information in a non-contact manner such as RF-ID.

  In addition, the production management system according to the present invention may be constructed by applying to a system that uses automated guided carriages by automated conveyance.

  Next, a specific implementation example of the production management system will be described with reference to FIG.

  FIG. 12 shows a form in which the workpiece is transferred from the process K1 for processing the workpiece using the apparatus 100 to the process K2 for processing the workpiece using the apparatus 200. When the workpiece is mounted on the workpiece conveyance carriage 1 at the workpiece loading point P1, the workpiece conveyance carriage 1 is provided with the workpiece loading information and workpiece conveyance carriage information of the workpiece to be loaded. Thereafter, the workpiece is transferred to the next process by the workpiece transfer carriage 1. At the workpiece transfer destination P2 of the next process, the workpiece transfer cart information given to the workpiece transfer cart 1 is read by the management system 10 and collated with information stored in advance in the management system 10, and determined based on the operation rules. Is done. If the determination result is an operation rule violation, the warning device 20 issues a warning. If the determination result is not a violation of the operation rule, the loaded work information is read by the management system 10, production progress information is created based on the information, and the production progress information is displayed on the display device 30.

  Next, the operation of the entire production management system will be described with reference to FIG.

  FIG. 13 is a flowchart of production progress management in the production management system and operation management related to the work conveyance carriage.

  First, the operation rule and production plan (FIG. 8) of the work transport carriage 1 are input to the management unit 11 of the management system 10 using the input unit 12 before the production starts.

  Next, the usage to be applied to each workpiece conveyance cart 1 is determined, and the workpiece conveyance cart usage number is stored in the workpiece conveyance cart information storage unit 4 provided in the workpiece conveyance cart 1 in the management system 10. Enter from. Thus, preparations before starting production are completed.

  When the work is mounted on the work transport carriage 1 after the start of production, the mounted work information transmitted from the mounted work information input section 13a is received and stored by the mounted work information storage section 3 of the work transport carriage 1 ( Step S1). The mounted work information includes a work type, the number, and a mounted work time (FIG. 4). Among the mounted work information, the type and number of works are created in advance from a production plan (FIG. 8) managed by the management unit 11 of the management system 10.

  Next, the workpiece conveyance cart information transmitted from the workpiece conveyance cart information input unit 13c is received and stored by the workpiece conveyance cart information storage unit 4 of the workpiece conveyance cart 1 (step S2).

  Next, the workpiece is conveyed to the next process.

  At the workpiece transfer destination, the workpiece transfer cart information transmitted from the workpiece transfer cart storage unit 4 is received by the workpiece transfer cart information acquisition unit 13d (step S3).

  The workpiece conveyance carriage information is checked against the information of the management unit 11 and it is determined whether or not there is a violation of operation rules (step S4).

  Specifically, one of the workpiece conveyance carriage information, the workpiece conveyance carriage usage number is collated with the data of the usage storage database (FIG. 7) stored in the management unit 11, and the workpiece conveyance is performed using the usage storage database. It is determined whether or not they match. If the usage does not match and it is determined that the operation rule is violated, warning information is created (step S5). Based on this warning information, a warning is issued by the warning device 20 (step S6, FIG. 10A).

  In addition, the workpiece conveyance carriage number on the other side of the workpiece conveyance carriage information is collated with the workpiece conveyance carriage number stored in the management unit 11, and it is determined whether or not the workpiece is conveyed in the order of the scheduled number (step). S4). If the order is different and it is determined that the operation rule is violated, warning information is created (step S5). Based on this warning information, a warning is issued by the warning device 20 (step S6, FIG. 10B).

  On the other hand, when it is determined that there is no violation of the operation rules, the mounted work information transmitted from the mounted work information storage unit 3 is received by the mounted work information acquisition unit 13b of the management unit 11 (step S7). This mounted work information is stored in a production performance database provided in the management unit 11 of the management system 10, and a new production performance database is created (step S8).

  Then, production progress information is created based on the production performance database (step S9) and displayed on the display device 30 (step S10). For example, production results are displayed (FIG. 11).

  Next, the operation for the tact time management of the production management system will be described with reference to FIG.

  FIG. 14 is an operation flowchart for work tact time management in the production management system.

  First, the mounted workpiece information acquisition unit 13b receives the mounted workpiece information transmitted from the mounted workpiece information storage unit 3 at the workpiece transfer destination (step S11). At this time, the time when the mounted work information is acquired is stored by the processing unit 14. The processing unit 14 continues to measure the time during which the work stays in the process from the loaded work information acquisition time (step S12). Whether the work stay time exceeds the tact time by comparing the work stay time from the mounted work information acquisition time with the tact time set in advance in the production plan (FIG. 8) at regular time intervals or in real time. It is determined whether or not (step S13). As a result, if the work stay time does not exceed the tact time, the process returns to step S12. If the work stay time exceeds the tact time, tact time excess warning information is created (step S14). The warning device 20 displays the warning information shown in FIG. 10C based on the tact time excess warning information. It should be noted that the measurement of the staying time ends when the mounted workpiece information is read by the mounted workpiece information acquisition unit 13b when the workpiece is transported to the next process.

  The production management system according to the present invention may be realized as a production management program in which the above-described procedure is stored in a program format. The target of the present invention may be the program itself, or the program stored in a computer-readable recording medium.

  In the present invention, as the recording medium, for example, a ROM itself may be a program medium, or a program reading device is provided as an external storage device (not shown), and the recording medium is inserted therein. It may be a readable program medium.

  Here, the program medium is a recording medium configured to be separable from the main body, and is a magnetic disk system such as FD (flexible disk) or HD (hard disk), CD-ROM / MO / MD / DVD, or the like. There are optical disk systems, card systems such as IC cards / optical cards, semiconductor memory systems using mask ROM, EPROM, EEPROM, flash ROM, and the like.

  Further, in the present invention, the system configuration is not connectable to a communication network including the Internet. However, when the system configuration is connectable to the communication network, it is fluid to download a program from the communication network. Or a recording medium holding the program.

It is a system configuration figure of a production management system in an embodiment of the invention. It is a whole block diagram of the workpiece conveyance trolley | bogie in embodiment of this invention. It is a schematic block diagram of the management system in embodiment of this invention. It is explanatory drawing which shows an example of the mounting work information in embodiment of this invention. It is explanatory drawing which shows an example of the workpiece conveyance trolley | bogie information in this Embodiment. It is explanatory drawing which shows an example of the information display in the trolley | bogie information display part with which the workpiece conveyance trolley | bogie in this embodiment is equipped. It is explanatory drawing which shows an example of the information stored in the use storage database in this Embodiment. It is explanatory drawing which shows an example of the production plan in embodiment of this invention. It is explanatory drawing which shows an example of the production performance database in this Embodiment. (A) is explanatory drawing which shows an example of the warning display of the use violation in embodiment of this invention, (b) is explanatory drawing which shows an example of the warning display of the first-in first-out violation in this embodiment, (c () Is an explanatory view showing an example of a tact time warning display in the embodiment of the present invention. It is explanatory drawing which shows an example of the production progress display in the display apparatus in this Embodiment. It is explanatory drawing which shows an example of the production form of the factory to which the production management system in this Embodiment is applied. It is a flowchart figure about the management of the production progress of the production management system in this embodiment, and the operation management regarding a workpiece conveyance trolley | bogie. It is an operation | movement flowchart figure about the tact time of the workpiece | work in the production management system in embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Work conveyance trolley 2 Cart 3 Mounted work information storage part 4 Work trolley information storage part 5 Cart information display part 10 Management system 11 Management part 12 Input part 13 Information input acquisition part 13a Mounted work information input part 13b Mounted work information acquisition part 13c Work conveyance cart information input unit 13d Work conveyance cart information acquisition unit 14 Processing unit 20 Warning device 30 Display device

Claims (18)

A production system production management system that transports a workpiece using a carriage from any process to the next process, a workpiece conveyance carriage that conveys the workpiece, a management system that manages the workpiece conveyance carriage and the workpiece, a warning device, A display device,
The workpiece transfer carriage includes a carriage on which a workpiece is mounted, a mounted work information storage unit in which mounted work information of the mounted work mounted on the carriage is stored in a state where the management system can input and acquire the work, and A workpiece conveyance carriage information storage unit in which the given workpiece conveyance carriage information is stored in a state that can be input and acquired by the management system;
The management system includes an operation rule that defines the operation of the work carriage, a production result database, a management unit that manages a production plan that is a basis for creating the mounted work information, and an input that inputs the operation rule and the production plan. An information input acquisition unit for inputting and acquiring the mounted work information and the work transport carriage information by communicating with the mounted work information storage unit and the work transport cart information storage unit, and at least operation violation warning information or tact A processing unit that creates any one of the time excess warning information and calculates production progress information from the mounted work information and the production performance database,
The processing unit collates the work conveyance carriage information with the operation rule to determine an operation rule violation of the work conveyance carriage, and if the operation rule is violated, creates the operation violation warning information, or the production plan While measuring the time that the workpiece exists in the process, and if the workpiece exceeds the takt time of the production plan, the takt time exceeded warning information is created,
The warning device issues a warning based on the operation violation warning information or the tact time excess warning information, and the display device displays the production progress information.   The production management system according to claim 1, wherein the workpiece transfer carriage includes a carriage information display unit that displays at least one of the mounted workpiece information and the workpiece transfer carriage information.   The production management system according to claim 1, wherein the mounted work information includes at least one piece of information among a type of work to be mounted, the number of works, and a work mounting time.   The production management system according to any one of claims 1 to 3, wherein the workpiece conveyance carriage information includes at least one piece of information among a workpiece conveyance carriage number and a usage number of the workpiece conveyance carriage.   The management unit has a function of generating the work transfer carriage number with a serial number by referring to the work transfer carriage information generated immediately before, and the work transfer carriage number is a serial number. The production management system according to claim 4. A production management method for a production system that transports a workpiece using a carriage from any process to the next process,
When mounting a workpiece on a workpiece transfer carriage in any process,
Mounted work information storage procedure for storing the mounted work information of the work to be mounted on the work transport carriage created in advance based on the production plan in the mounted work information storage section provided in the work transport truck;
Work transfer carriage information storage procedure for storing work transfer carriage information created in advance based on a production plan in a work transfer carriage information storage unit provided in the work transfer carriage;
In the next process,
A workpiece transfer carriage information acquisition procedure for acquiring the workpiece transfer carriage information from the workpiece transfer carriage information storage unit;
Judgment procedure for checking an operation rule violation by comparing an operation rule that defines an operation rule of the work transport cart and the work transport cart information;
When the result of the judgment is an operation rule violation, a warning procedure for issuing a warning with a warning device;
When the result of the determination is not an operation rule violation, the mounted work information acquisition procedure for acquiring the mounted work information from the mounted work information storage unit;
A production management method comprising: a display procedure for calculating production progress information from the on-board work information and a production performance database stored in a management system and displaying the production progress information on a display device.   The production management method according to claim 6, wherein the work conveyance carriage includes a procedure for displaying at least one of the mounted work information and the work conveyance carriage information on the carriage information display unit.   The production management method according to claim 6 or 7, wherein the mounted work information includes at least one piece of information among a type of work to be mounted, the number of works, and a work mounting time.   The production management method according to any one of claims 6 to 8, wherein the workpiece transfer carriage information includes at least one piece of information among a workpiece transfer carriage number and a use number of the workpiece transfer carriage.   10. The procedure for generating the work transfer cart number by serial number with reference to the previous work transfer cart information generated before the work transfer cart information storing procedure. The production management method described in 1. A production management method for a production system that transports a workpiece using a carriage from any process to the next process,
A work arrival time acquisition procedure for acquiring a work arrival time;
A work stay time acquisition procedure for measuring a work stay time, which is a time during which the work stays in the arbitrary step;
A tact time excess determination procedure for comparing the tact time stored in the production plan with the work stay time acquired in the work stay time acquisition procedure;
When the work stay time exceeds the tact time in the tact time excess determination procedure, the tact time excess warning information creation procedure for creating the tact time excess warning information;
And a tact time excess warning information output procedure for outputting the tact time excess warning information created in the tact time excess warning information creation procedure. A production management program for a production system that transports a workpiece using a carriage from any process to the next process,
When mounting a workpiece on a workpiece transfer carriage in any process,
A mounted work information storage step for storing the mounted work information of the work to be mounted on the work transport cart prepared in advance based on the production plan in a mounted work information storage section provided in the work transport cart;
A workpiece conveyance carriage information storage step for storing workpiece conveyance carriage information created in advance based on a production plan in a workpiece conveyance carriage information storage unit provided in the workpiece conveyance carriage;
In the next process,
A workpiece transfer carriage information acquisition step of acquiring the workpiece transfer carriage information from the workpiece transfer carriage information storage unit;
A determination step of checking an operation rule violation by checking an operation rule that defines an operation rule of the work transport cart and the work transport cart information;
When the result of the determination is an operation rule violation, a warning step for issuing a warning with a warning device;
When the determination result is not an operation rule violation, the mounted work information acquisition step for acquiring the mounted work information from the work transport cart information storage unit;
A production management program comprising: a display step of calculating production progress information from the mounted work information and a production performance database stored in a management system and displaying the production progress information on a display device.   The production management program according to claim 12, wherein the work transport carriage includes a step of displaying at least one of the mounted work information and the work transport truck information on the carriage information display unit.   The production management program according to claim 12 or 13, wherein the mounted work information includes at least one piece of information among a type of work to be mounted, the number of works, and a mounting time of the work.   The production management program according to any one of claims 12 to 14, wherein the workpiece transfer carriage information includes at least one piece of information among a workpiece transfer carriage number and a use number of the work transfer carriage.   16. The step of generating the work transfer carriage number with a serial number with reference to the previous work transfer carriage information generated before the work transfer carriage information storing step. The production management program described in 1. A production management program for a production system that transports a workpiece using a carriage from any process to the next process,
A workpiece arrival time acquisition step for acquiring a workpiece arrival time;
A work stay time acquisition step of measuring a work stay time, which is a time during which the work stays in the arbitrary process;
A tact time excess determination step for comparing the tact time stored in the production plan with the work stay time acquired in the work stay time acquisition procedure;
If the work stay time exceeds the tact time in the tact time excess determination procedure, a tact time excess warning information creating step for creating tact time excess warning information;
A production management program comprising: a tact time excess warning information output step for outputting the tact time excess warning information created in the tact time excess warning information creation step.   A computer-readable recording medium storing the production management program according to any one of claims 12 to 17.

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