JP2006293532A - Product manufacturing system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a product manufacturing line capable of learning the production history of parts assembled in each product without preparing bar code readers at all the assembly lines, lowering the operation efficiency, and incurring operation loss like reading the bar codes for showing the part lots two times at a part acceptance and each part assembly of the manufacturing process. <P>SOLUTION: The product manufacturing system attaches a tag with the recorded serial number of a parts box to the parts box storing the parts. The system comprises the first transmitter for transmitting the serial number of the parts box and parts information to the production history database, and the second transmitter set up at the storage site for parts assembly of each process of the assembly line for reading the serial number of the parts box recorded on the tag to transmit the production history database. The production history database stores the serial number of the parts box transmitted by the second transmitter, and stores the serial number of the parts box tied with the product serial number in the assembly line. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a product production system, and more particularly, to a product production system having a database that manages a part box serial number and a product serial number of a vehicle on an assembly line in association with each other.

  Conventionally, finished products (automobiles, etc .: hereinafter referred to as “products”) produced at a finished product factory (hereinafter referred to as “factory”) are accepted by the parts receiving department of the factory, with parts received from a parts manufacturer (part factory) The logistics department in the factory transported the product to the production process, and the workers assembled the product in each assembly process.The serial number of the product in which the part was assembled (hereinafter referred to as “product serial number”) and the assembled part The production lot number was recorded in a ledger etc. by the operator and stored and stored in association with the product serial number.

  As an example of systematizing these operations, Patent Document 1 attaches a barcode label of a product serial number to a product that moves on a production line, and attaches it to a part to be assembled in the process of assembling the part to this product. A technique for recognizing a part lot number by reading a bar code and storing and storing the product serial number of the product and the production lot number of the part in association with each other as electronic information is disclosed.

  On the other hand, in Patent Document 2, a bar code label indicating a part production lot number and a part type is attached to a part box containing a part to be assembled to a product, and the product serial number is also represented by a barcode label on the product to which the part is assembled. A method of pasting, reading a part lot change at a part box replacement timing, and associating a product serial number and a part lot number as electronic information is disclosed.

  However, with the conventional method of associating the product serial number with the part lot number, a barcode reader is arranged for every part assembly process in the manufacturing process, and at the timing when all part lots are switched, the parts box Must read the barcode. For this reason, it takes time to read, and the part assembly worker has to do extra work, which increases the work man-hours, and there is a problem that the labor of the workers becomes insufficient when switching parts lots and the efficiency is poor. It was.

Also, the parts receiving department at the production plant that receives various parts sent from the parts manufacturer reads the lot number (barcode) affixed to the received parts box, and the type of parts ordered by the delivered parts. Since it was confirmed whether or not the quantities were the same, there was an operation loss in which the barcode representing the parts lot was read twice by the parts receiving department and each parts assembling department in the manufacturing process.
JP 7-36997 A JP 63-170774 A

  The problem of the present invention is that a barcode reader must be arranged in every part assembling process of the manufacturing process, which is a problem in the conventional method of associating the product serial number with the part lot number, It takes a long time to read the barcode of the parts box at the timing of switching the parts lot, and the part assembly worker has to do extra work, which increases the work man-hours when switching parts. This is to eliminate the shortage of man-hours for workers and the inefficiency. It is also an object of the present invention to eliminate the work loss of reading the barcode representing the parts lot twice by the parts receiving department and each parts assembling department in the manufacturing process.

  The object of the present invention is to eliminate the need to read and arrange barcodes in all assembling processes in view of the above-mentioned problems, work efficiency does not deteriorate, and a barcode representing a parts lot is assigned to each part receiving department and each manufacturing process. An object of the present invention is to provide a product production system capable of knowing the manufacturing history of parts incorporated in each product without the work loss of reading twice in the parts assembling department.

    In order to achieve the above object, the product production system according to the present invention is configured as follows.

  In the first product production system (corresponding to claim 1), the parts carry-in management unit manages the carry-in of parts, the assembly line control part supplies the parts to the assembly line, assembles them into the product, and manufactures the product. A product production system that performs linking management in a history database, wherein a parts carry-in management unit attaches a tag in which a part box serial number is recorded to a part box that contains a part, and the part box serial number recorded in the tag The first transmitter that transmits the parts information contained in the parts box to the manufacturing history database, and the parts box serial number recorded on the tag provided at the parts assembly place in each process of the assembly line is read and sent to the manufacturing history database. The manufacturing history database stores the parts box serial number read at the parts assembly place and transmitted by the second transmitting part, Characterized by storing in association with the product serial number of the product of the serial number and assembly line.

  In the above configuration, the second product production system (corresponding to claim 2) is preferably characterized in that the first transmission unit is preferably provided on the part manufacturer side and the manufacturing history database is provided on the product manufacturer side.

  A third product production system (corresponding to claim 3) is characterized in that, in the above configuration, the part box serial number transmitted by the second transmission unit is preferably inquired in the manufacturing history database.

  In a fourth product production system (corresponding to claim 4), in the above configuration, the manufacturing history database preferably includes a component box remaining number calculation unit that calculates a remaining number of component boxes. It is characterized by including a parts box delivery instruction section that issues a parts box delivery instruction based on the calculated number of remaining parts boxes.

  A fifth product production system (corresponding to claim 5) is characterized in that, in the above-described configuration, a plurality of types of vehicles are preferably assembled on an assembly line.

  A sixth product production system (corresponding to claim 6) is characterized in that, in the above configuration, the tag is preferably formed of an IC chip.

  The seventh product production system (corresponding to claim 7) is characterized in that, in the above configuration, the part information stored in the part box preferably stored together with the part box serial number is manufacturing history information. It is attached.

  In the eighth product production system (corresponding to claim 8), the parts carry-in management unit manages the carry-in of parts, and the assembly line control part supplies the parts to the assembly line and assembles them into the product to produce the product. A product production system that performs linking management in a history database, wherein a parts carry-in management unit attaches a tag in which a part box serial number is recorded to a part box that contains a part, and the part box serial number recorded in the tag Recorded in tags provided in the first transmission unit that transmits the parts information contained in the parts box to the manufacturing history database, the automatic warehouse that stores the delivered parts box, and the parts assembly place in each process of the assembly line A second transmission unit that reads the serial number of the parts box and transmits it to the production history database, and the production history database is read at the component assembly place and transmitted by the second transmission unit. Storing the parts box serial number, characterized by storing the product serial number of the product in the parts box serial number and assembly line cord attached to.

  In a ninth product production system (corresponding to claim 9), in the above configuration, the manufacturing history database preferably includes a component box remaining number calculation unit for calculating a remaining number of component boxes. It is characterized by including a parts box delivery instruction unit that issues a parts box delivery instruction to the automatic warehouse based on the calculated number of remaining parts boxes.

  According to the present invention, it is not necessary to read and arrange barcodes in all assembling processes, work efficiency is not deteriorated, and barcodes representing parts lots are divided into two parts by the parts receiving department and the parts assembling departments of the manufacturing process. The effect of eliminating the work loss of reading once is obtained. Also, the manufacturing history database stores the part name and part lot number stored in the part box with the part box serial number, and links the part box serial number and the product serial number that are read at the part assembly location. Because it is stored, if you know the product serial number of the manufactured vehicle, you can know the parts box serial number that contains the parts mounted on the vehicle, and thereby know the manufacturing history of the parts mounted on the vehicle Can do. Conversely, the part box serial number in which the part is contained can be found from the part name and part lot number, and the product serial number of the vehicle in which the part is mounted can be found from the part box serial number. In addition, according to the present invention, the parts box serial number transmitted by the second transmission means is referred to in the manufacturing history database, so that the part acceptance procedure can be simplified.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments (examples) of the invention will be described with reference to the accompanying drawings.

  FIG. 1 shows a configuration of a product production system according to the present invention. In this embodiment, the product is, for example, an automobile. In the production factory 10, a wide variety of vehicles are produced in an assembly line 11 that produces a variety of vehicles (various specifications).

  The vehicle production system 20 includes an assembly line control (ALC) system 21, an assembly line 11, a manufacturing history database 22, and parts receiving departments 23-1, 23-2, 23-3 installed in the production factory 10. , A parts box delivery instruction unit 25, a production planning system 26, a specification management system 27, a parts ordering system 28 that can be installed even in a management department outside the production factory 10, and an invoice issuing system 29- installed in each parts manufacturer 1, 29-2, 29-3 and component information transmission systems 40-1, 40-2, 40-3. In the figure, steps 1 to 9 schematically represent each step in the assembly line 11. For example, process 1 is a piping and wiring unit process, process 2 is an engine room process, process 3 is an interior unit process, process 4 is an exterior unit process, process 5 is a powertrain exhaust gas unit process, and process 6 is Liquid injection step, step 7 is a tire, spare tire step, step 8 is a seat attachment step, step 9 is a door attachment step, and the like. Display terminal devices 30-1, 30-2,... 30-9 are provided in the vicinity of the production line in each process. In addition, non-contact readers 103-1, 103-2,... 103-9 are provided at the parts assembly place in each process of the assembly line. Each of the above systems is connected by a telecommunication line, and a communication relationship is formed so that signals, data, and information can be transmitted and received through this telecommunication line.

  The ALC system 21 is produced on the display terminal devices 30-1, 30-2,... 30-9 of each process of the assembly line 11 according to the production plan (production order plan) received from the production plan system 26. The product specifications are transmitted and displayed, and the production status on the assembly line 11 is monitored. Further, the progress status of the assembly line 11 is sent to the manufacturing history database 22.

  The assembly line 11 is a line in which various conveyors of a flow work method are combined, and a large number of various components and sub-assembled component units are assembled to the body flowing through the line. A variety of products (various specifications) are produced in the assembly line 11 at the production factory 10 in this embodiment.

  In the manufacturing history database 22, the serial number of the parts box (parts box serial number) delivered to each process from the parts receiving departments 23-1, 23-2, and 23-3 is used as a part assembly place for each process on the assembly line. Received with arrival time when arriving. In addition, the manufacturing history database 22 receives the specifications of the products currently in each process transmitted from the ALC system 21, and uses the information to collate the parts to be assembled in the products currently in each process with the specification management system 27. Then, the part name to be assembled is acquired, and it is determined that the part is assembled to the product by the worker from the part box of the part in the process. The part box serial number and the product serial number of the part box containing the part are linked and stored. Further, the manufacturing history database 22 includes a component box remaining number calculation unit 22a that calculates the remaining number of component boxes. The parts box remaining number calculating unit 22a includes a parts box leaving instruction unit 25 that calculates the number of remaining parts boxes and instructs the supply of the parts box of parts necessary for assembling the vehicle in the assembly line. The information is transmitted to the automatic warehouse 110 by the unit 25.

  The parts box leaving instruction unit 25 issues a parts box leaving instruction to the automatic warehouse based on the parts box remaining number calculated by the parts box remaining number calculating part 22a.

  The parts receiving departments 23-1, 23-2, and 23-3 are located in the assembly factory 10 and are attached to the delivered parts boxes using the parts receiving and dispensing systems 23-A, 23-B, and 23-C. A parts box serial number recorded on a tag made of an IC chip such as a wireless tag is read, and the parts box is temporarily stored in a storage space of an assembly factory. As this storage space, the automatic warehouse 110 disclosed in Japanese Patent No. 2559159 is used.

  FIG. 2 is a block diagram of the parts receiving / dispensing system. The parts receiving / dispensing system 23 -A (B, C) includes a control device 50, an input device 51, an output device 52, a conveyance component storage unit 53, and a storage device 57. The control device 50 controls the input device 51, the output device 52, the conveyance component storage unit 53, and the storage device 57. The input device 51 is a device for inputting the component box serial number read from the tag reading device 54 and inputting the component information from the ALC system 21. The output device 52 is a device that outputs information on a storage location where the parts box is stored or information on a storage location where the parts box is stored to the system of the automatic warehouse 110. The storage device 57 includes an empty storage place where the parts box can be stored, a storage place storage area 55 for storing a storage place where the parts box is already stored, and a parts box serial of a tag attached to the parts box. A parts box serial number storage area 56 for storing numbers is provided. In addition, a transport part storage unit 53 that stores a parts box transported from the automatic warehouse 110 is provided.

  In the case of the automatic warehouse 110, the parts box serial number recorded on the tag at the entrance of the automatic warehouse 110 is read by the tag reading device 54 and then automatically carried into a predetermined section by a crane or a conveyor (not shown). This reading is automatically read by the tag reading device 54 at the entrance of the automatic warehouse 110. The parts box serial number read from the tag reading device 54 is input from the input device 51 of the parts receiving / dispensing system 23A (B, C), and the control device 50 reads the empty storage location from the storage location storage area 55 of the storage device 57. The empty storage location is stored in the storage location storage area 55 together with the part box serial number, and the storage location information is output from the output device 52 to the control device of the automatic warehouse 110 (not shown). The parts box is carried into the storage location by a crane or a conveyor by the control device. Further, the parts receiving / dispensing systems 23 -A, 23 -B, and 23 -C detect the storage location where the corresponding type of parts box is stored based on the information received from the ALC system 21. In that case, when the parts are the same, it is desirable to pay out the parts boxes to the assembling process in the order of reading the parts box serial numbers recorded in the tags of the respective parts boxes. In the case of the automatic warehouse 110, when a necessary part is instructed from the ALC 21, the control device 50 retrieves the part box serial number of the part box containing the part from the storage device 40 from the storage area 56, and the part box The corresponding storage location is searched from the storage location storage area 55 by the serial number, and the information of the searched storage location is transmitted to the control device of the automatic warehouse 110. The control device controls the crane, conveyor, etc. The corresponding parts box is automatically transported to the parts exit.

  The parts box serial number reading / transmitting device (second transmitting unit) which is a non-contact reading device that reads the part box serial number recorded in the tag and transmits it to the manufacturing history database 22 at the parts assembly place in each process of the assembly line. 103-1,... 103-9 are provided. The parts box serial number reading / transmitting device 103-1,... 103-9, along with the parts box serial number recorded on the tag attached to the parts box carried into the assembly line, the time of delivery, and the manufacturing history database 22. Send to. The transmitted parts box serial number is inquired in the manufacturing history database.

  The production planning system 26 creates a production plan for products to be produced in the line 11 for producing a variety of products, and also creates a production ranking plan that determines the order of actual production in the factory according to the production plan. System.

  The specification management system 27 registers and manages part specifications used for various types of products. Specifically, a parts list for each vehicle type is registered, and if a vehicle type is specified, a part necessary for assembling the vehicle type can be searched.

  The parts ordering system 28 calculates the required amount of parts according to the produced production plan, determines the delivery date / time and quantity for each part manufacturer, and places an order.

  The in-stock slip issuing systems 29-1, 29-2, and 29-3 are installed in a parts manufacturer, and are used to identify the ordering information on the ordering side for the parts to be delivered when delivering to a product factory at a specified date and time. , Issue the attached product slip. At this time, based on the part order received from the part ordering system 28, a standard product slip of a unified standard is created. The actual product slip also includes a lot number, which is an arbitrary number for identifying a production lot of parts.

  In addition, a part manufacturer attaches a product slip that records the production lot number of a part to a part to be shipped, and a tag that records a part box serial number that identifies each part box on the part box that contains the part. Install.

  The component information transmission system (first transmission unit) 60 is provided in a component manufacturer and has the configuration shown by the block configuration diagram of FIG. 3. The control device 61, the input device 62, the storage device 63, and the component information A transmission device 64 is provided. The control device 61 controls the input device 62, the storage device 63, and the component information transmission device 64. The input device 62 and the storage device 63 constitute a component information reading storage device 65, which is recorded on the manufacturing lot number recorded on the actual product slip 67 of the component put in the component box 66 and the tag 68 attached to the component box. The component box serial number is read by the reading device 69, and the read signal is sent to the input device 62 by wire, wireless, or light, and stored as component information in which the component name, the read manufacturing lot number, and the component box serial number are associated with each other. The component information transmitting device 64 transmits the manufacturing lot number, the component box serial number, and the component name stored by the component information reading storage device 65 to the manufacturing history database 22 of the vehicle manufacturing factory for storage.

  Next, an example of the overall processing of the vehicle production system will be described with reference to the flowcharts of FIGS. 4 to 7, the process outline diagram of FIG. 8, and the tables shown in FIGS.

  First, a production plan for a product to be produced is created in a line for producing a variety of products by the production planning system 26 (step S20). This production plan usually includes, for example, the status of orders received from customers and expected production products other than orders, and initially shown in FIG. 9 for each MTC (model (M), type (T), color (C)). The number is set as shown in Table 1. In Table 1, column C10 represents MTC, column C11 represents vehicle type, column C12 represents normal or 4WD drive, column C13 represents domestic or export destination, and column C14 represents the number of vehicles. In the production planning system 26, by using the production order plan creation method included in this system, the order of products produced on the day (production order plan) is determined. Then, the production plan (production order plan) is transmitted to the parts ordering system 28 (step S21).

  Next, the part ordering system 28 that has received the production plan from the production planning system 26 retrieves the part specification from the specification management system 27 that registers and manages the part specifications used for various types of products, and creates the produced production plan. Accordingly, the required amount of necessary parts is calculated (step S22). This is done as follows. The parts used depend on the specifications of the products according to the MTC in the production plan that has been sent. These are managed by the specification management system 27, and Table 2 shown in FIG. 10 is obtained using this information. In Table 2, column C20 represents MTC, column C21 represents vehicle type, column C22 represents normal or 4WD drive, column C23 represents domestic or export destination, and column C24 uses part A. Column C25 indicates whether or not the component B is used, column C26 indicates the type of component C, and column C27 indicates the type of component D. As can be seen from Table 2, the parts A and B are used for all products produced on the day, but the parts C and D are different depending on the MTC. That is, C01 is used for vehicles with MTC of N, P, S, T, W, and X, and C02 is used for vehicles with MTC of Q, R, U, V, Y, and Z. The component D uses D11 for MTC N and Q, D12 for MTC P and R, D21 for MTC S and U, D22 for MTC T and V, and MTC W and Y Uses D31, and MTC uses X32 and D32. By combining Table 1 shown in FIG. 9 and Table 2 shown in FIG. 10, the number of parts necessary for production of the product on the day is calculated. This is shown in Table 3 shown in FIG. In Table 3, column C30 represents the part name, column C31 represents the MTC to be applied, and column C32 represents the required number of corresponding components. Based on the required amount (required number) of the parts shown in Table 3, the parts ordering system 28 determines the delivery date / time and quantity for each part manufacturer and places an order (step S23).

  The part manufacturer that has received the part order manufactures the part (step S24), and codes the part number / quantity / part lot information (manufacturing lot number) by the invoice issue system 29-1, 29-2, 29-3. An actual product slip with a machine-readable medium attached is created (step S25). At this time, the actual product slip issuing systems 29-1, 29-2, and 29-3 create actual product slips of a unified standard based on the part order received from the part ordering system 28. Next, the part information transmission system 60 reads the part name, the production lot number recorded on the actual product slip of the part put in the part box, and the part box serial number recorded on the tag attached to the part box (FIG. 8). (D1)), and stores the read part name, production lot number, and part box serial number as part information (FIG. 8 (D2)), and stores the stored part name, production lot number, and part box serial number in the vehicle. The data is transmitted to and stored in the manufacturing history database 22 of the manufacturing factory (step S26, FIG. 8 (D3)).

  FIG. 6 shows a processing flowchart in the component information transmission system 60. First, the component box serial number of the tag of the component box is read (step S261, FIG. 8 (D1)). Next, the actual product slip is read (step S262). The control device associates the parts box serial number, the part name of the actual item slip, and the lot number and stores them in the storage device (step S263, FIG. 8 (D2)). It is determined whether all the parts boxes to be shipped have been stored (step S264). If not completed, the process returns to step S261, and if completed, component information including the component name, component box serial number, and lot number is transmitted to the manufacturing history database 22 by the component information transmitting device 64 ( Step S265, FIG. 8 (D3)). After that, the product tag and the tag are attached to the parts box containing the parts and sent to the assembly factory (step S27, FIG. 8 (D5)).

  Next, as shown in FIG. 6, in the parts receiving department, when the parts are delivered, the tags attached to the delivered parts box using the parts receiving and dispensing systems 23-A, 23-B, and 23-C. The parts box serial number is automatically read by the tag reader 54 (step S28, FIG. 8 (D6)), and the parts box is temporarily stored in the storage space of the assembly factory. At this time, in the case of the automatic warehouse 103, the parts box is automatically conveyed to a predetermined section by a crane or a conveyor. At the same time as reading the actual product slip, the location where the parts box is temporarily stored is input to the parts receiving / dispensing system 23-A, 23-B, 23-C, and the parts receiving / dispensing system 23-A, 23-B, 23-C is stored (step S29).

  Next, the processing of this system when an automobile is produced on the assembly line (FIG. 8 (D7)) will be described with reference to the flowchart of FIG. First, the production planning system 26 transmits a production plan (production order plan) to the ALC system 21 (step S40). Receiving the production plan, the ALC system 21 creates a production setup instruction for each process (step ST41). The prepared setup instructions in each process are transmitted to the line terminals 30-1, 30-2,... 30-9 on the line side of the production line 11 (step S42). The line terminals 30-1, 30-2,... 30-9 display the received setup instruction on the display device (step S43). The worker performs assembly work in each process according to the setup. The ALC system 21 monitors the production status in the assembly line 11 (FIG. 8 (D8)), and sends the progress status of the assembly line to the manufacturing history database 22 (step S44, FIG. 8 (D9)). Next, the part box delivery instruction unit 25 transmits the part box delivery instruction of the parts necessary for each process to the automatic warehouse 110 of the part receiving / dispensing system 23-A, 23-B, 23-C (step S45). ). In the parts receiving / dispensing systems 23-A, 23-B, and 23-C that have received the parts arrangement instruction, the parts are paid out to each process (step S46). At that time, the parts receiving / dispensing system 23-A, 23-B, 23-C detects the location where the serial number of the corresponding type of parts box is stored based on the part information received from the ALC system 21, and Display location. The worker takes out the corresponding parts box from the displayed storage location, and transports the transport vehicle on which the parts box is placed on the carry-in path, or transports it to the line side by the transport robot. In the case of an automatic warehouse, the parts box is automatically conveyed to the exit port by a conveyor or a crane. The parts box serial number reading / transmitting device 103-1,... 103-9 at the parts assembly place reads the parts box serial number stored in the tag attached to the parts box (step S47, FIG. 8 (D10)). ). Part information such as the part name and manufacturing lot number of the corresponding part is stored in the manufacturing history database 22.

  The manufacturing history database 22 receives the part box serial number of the part box of each part specification delivered to each process from the parts acceptance / dispensing system 23-A, 23-B, 23-C via the second transmission unit. . The manufacturing history database 22 receives the specifications of the products currently in each process transmitted from the ALC system 21 (step S42), and uses the information to manage the specifications of the parts to be assembled in the products currently in each process. The part name to be assembled is acquired by collating with the system (step S48), and it is determined that the part is assembled to the product by the worker from the part box of the part in the process. The parts box serial number and product serial number are linked and stored (step S49). It is determined whether or not the number of parts in the parts box has reached a predetermined number (step S50). If the number of parts reaches the predetermined number, the fact that the number of parts has reached the predetermined number is transmitted to the parts box delivery instruction unit 25 (step S51). The parts box delivery instruction unit 25 instructs the automatic warehouse to issue the parts box (step S45).

  Steps S27 to S50 will be described more specifically with reference to the tables shown in FIGS. Parts delivered from a parts maker are housed in a parts box. However, since the parts box is different for each part, the number of parts accommodated per part box is different. This is shown in Table 4 shown in FIG. In Table 4, a column C40 represents a component name, and a column C41 represents a component box accommodation number. For example, component A has a component box accommodation number of 50, and component B has a component box accommodation number of 60. Further, the production ranking plan created by the production planning system is shown in Table 5 shown in FIG. In Table 5, column C50 represents the product serial number, column C51 represents the vehicle type, column C52 represents 4WD or normal drive, column C53 represents the domestic or export destination, column C54 represents MTC, column C55 represents the line insertion time. The production process is shown in Table 6 shown in FIG. In Table 6, a column C60 represents a process, a column C61 represents a part to be traced, and a column C62 represents an arrival time after input. For the sake of simplicity, assuming that the product production line flows in 1 minute tact (the time given to the work of one process), if the time to the work place is added to the time put in the line, the relevant The time spent working on the product can be calculated.

  In other words, as shown in Table 6 of FIG. 14, a product to be worked arrives at step 10 which is a step of assembling the part C 10 minutes after the line is put in. As shown in Table 5 of FIG. 13, the product serial number 15 is input at 8:44, so that the process 10 arrives at 9:54.

  In each process, since there is no part to be assembled in the product, the work cannot be performed. Therefore, the MTC product to be assembled is planned to be transported from the parts receiving department to each process before reaching each process. For example, the part A used on the day assembled in the process 3 is the part A at the time of line entry 8: 30 + 8/333 when the product serial number 1 which is the first product of the day arrives. Is required. Although it may arrive at the last minute, it is planned to arrive at 8:28 with a certain margin (for example, 5 minutes).

  On the other hand, if all parts used on the day are transported at the same time, the space in the line workshop will be narrowed, and mistakes may occur if there are similar parts. At a certain time, a parts transportation plan is prepared in which the required amount is stored in the parts box and delivered. For example, as shown in Table 4 of FIG. 12, in the case of the part A, since the number of parts stored in one part box is 50, only 50 parts are stored on the line side at the time described above (8:28). Parts are transported. Since this part A is used for all products manufactured on the same day, one piece is consumed per minute and the 50th unit from the start of manufacture, and the part box for part A will be empty after 50 minutes.

  The ALC 21 calculates from the relationship between the production order plan and the product specifications, and creates the next parts transportation plan. Based on this plan, the part A from the parts receiving department transports the second part box to the process 3 at 9:18.

  As in the case of the part A, it is easy when there is a single part to be assembled in the product in one process, but in a process having a plurality of types of parts assembled in the process, the result is as shown in Table 7 shown in FIG. (A) in Table 7 represents the part number C401 (4WD) for lot number C401, column C70 represents the number of components, and column C71 represents the product serial number of the assembled vehicle. (B) in Table 7 represents the part number C2 for the lot number C20, column C72 represents the number of components, and column C73 represents the product serial number of the assembled vehicle. Further, (c) in Table 7 represents the part number C402 (4WD) for the lot number C402, the column C74 represents the number of components, and the column C75 represents the product serial number of the assembled vehicle. (D) of Table 7 represents the part number C2 for the lot number C20, column C76 represents the number of components, and column C77 represents the serial number of the assembled vehicle. (E) in Table 7 represents the part number C03 (4WD) for lot number CC03, column C78 represents the number of components, and column C79 represents the serial number of the assembled vehicle. (F) in Table 7 represents the part number C20 (2WD) for the lot number C20, the column C80 represents the number of components, and the column 81 represents the serial number of the assembled vehicle. For example, as shown in Table 6 of FIG. Further, as shown in Table 4 of FIG. 12, there are two types of parts C, 4WD and normal 2WD. Further, the number of parts C accommodated in the parts box is different for 4WD and 2WD. That is, as shown in Table 4, the number is 25 for C02 (for 4WD) of component C and 20 for C01 (for 2WD).

  Referring to the production order plan table, the parts are used as shown in Table 7 shown in FIG. That is, the product for the day arrives at the assembly process 10 for the part C at 8: 30 + 9: 8: 39. The first assembled part C (for 4WD) is transported at 8:34, 5 minutes before 8:39. The parts box contains 25 parts C (for 4WD). Referring to the production order of products, since the same MTC products up to serial number 25, the same part C (for 4WD) is used (Table 7 (a)), but the MTC changes from serial number 26. As shown by an arrow Y10 in FIG. 15, the used part changes, and the part C (for 2WD) is used (Table 7 (b)). Part C (for 2WD) contains 20 parts boxes. It will be transported at 8:59, 5 minutes before 9:04, when parts C (for 2WD) will be used.

  In this state, in the process 10 for assembling the part C, the 4WD for the part C and the 2WD for the part C are placed at the same time. That is, in this example, from 8:59 to 9: 3, two types of parts boxes are placed under the operator of the process 10. Furthermore, according to the production order plan, the part C (for 2WD) will be empty after 20 minutes, so the next part box must be transported to the process 10 5 minutes before 9:24. . When the parts box is changed with the same parts as indicated by the arrow Y11, the parts production lots of the manufacturers that produce the parts may be different.

  According to the production order plan, there is an MTC product that assembles part C (for 4WD) in process 10 at the stage when five pieces from the second part box of part C (for 2WD) shown in Table 7 (d) are used. come. Since the parts box of part C (for 4WD) shown in Table 7 (a) has been emptied by assembling to the product at 9: 3, serial number 51 is placed on the line at 9:20. It is put in, and as shown by the arrow Y12, use begins at 9:30, 10 minutes after that. Therefore, the second part box of the part C (for 4WD) shown in Table 7 (c) is transported at 9:25. At this stage, a parts box in which 15 parts C (for 2WD) shown in Table 7 (d) remain and a second parts box of parts C (for 4WD) shown in Table 7 (c) are placed. Will be. After using part C shown in Table 7 (c), use part C (for 4WD) shown in Table 7 (e), use up to 9 parts, and then use part C (for 2WD) shown in Table 7 (d) ) As shown by an arrow Y13. When 20 parts C (for 2WD) shown in Table 7 (d) have been used, the parts are assembled from the parts box of the next part C (for 2WD) shown in Table 7 (f) as indicated by arrow Y14.

  FIG. 16 is a diagram showing the flow of vehicles on the assembly line 11 when this system is used. Vehicles with product serial numbers 001 to 025 are vehicle type A, vehicles with product serial numbers 026 to 047 are vehicle types B, vehicles with product serial numbers 048 to 050 are vehicles with vehicle type C, and product serial numbers 051 to 076. Vehicle type D, vehicle serial number 077 to 085, vehicle type E, and vehicle serial number 086 to 121, vehicle type F flows. At this time, the vehicle type A, the vehicle type D, and the vehicle type E are the parts A (for 4WD), the parts B, and the parts C, and the vehicle types B, C, and F are the parts A (for 2WD), the parts B, and the parts C. It is done. In the vehicle of product serial number 001, parts A (4WD), B, and C whose lots are switched are used and flowed to the assembly line 11. When it becomes the vehicle of the product serial number 026, since it is changed to the vehicle type B, the part A (4WD) is changed to the part (2WD) and becomes a new lot. Further, in the vehicle with the product serial number 047, the lot switching of the part A (2WD) is performed, and when the vehicle has the product serial number 051, both the parts A (4WD) and B are switched over. The part C is lot-switched in the vehicle having the product serial number 061, and the part A (2WD) is lot-switched in the vehicle having the product serial number 076. Parts A (2WD) and B in the vehicle of product serial number 101 are lot-switched. In addition, the part C is lot-switched in the vehicle having the product serial number 121. In this manner, lot switching is performed on the parts assembled in the vehicle.

  Each time the parts box is transported to the line, the serial number is recorded in the manufacturing history database 22 in association with the product serial number of the vehicle and the parts box serial number. For example, in this example, the part A contained in the parts box of the parts box serial number 1 from the vehicle of the product serial number 001, the parts B contained in the parts box of the parts box serial number 2, and the parts of the parts box serial number 3 It is recorded that the part C contained in the box is mounted, and the part A (4WD) contained in the part box of the part box serial number 1 is mounted up to the vehicle of the product serial number 025. The part A (4WD) contained in the parts box of the parts box serial number 4 is mounted on the vehicle having the product serial numbers 051 to 075, and the parts contained in the parts box of the next parts box serial number 5 are the product serial numbers. It is mounted on vehicles from 076 to 085. The part B contained in the part box of the part box serial number 6 is mounted on the vehicles having the product serial numbers 051 to 100. The part C contained in the parts box of the parts box serial number 7 is mounted on the vehicles having the product serial numbers 061 to 120. The part A (2WD) contained in the part box of the part box serial number 8 is mounted on the vehicles having the product serial numbers 026 to 046. The part A (2WD) contained in the part box of the part box serial number 9 is mounted on the vehicle having the product serial numbers 047 to 100. The part A (2WD) and the part B of the part box serial number 12 which were in the part box serial number 10 and the part box serial number 12 are mounted in the vehicles of the product serial numbers 101 to 121 and enter the parts box of the part box serial number 11. The part C that has been mounted is mounted on the vehicle having the product serial number 121. In the manufacturing history database 22, the vehicles with product serial numbers 001 to 025 are in the parts box with the parts box serial number 1, the parts box with the parts box serial number 2, and the parts box with the parts box serial number 3. It is recorded that the part is mounted. It is recorded that vehicles with product serial numbers 026 to 046 are equipped with the parts box with the parts box serial number 2, the parts with the parts box serial number 3, and the parts that were in the parts box with the parts box serial number 8. The Vehicles with product serial numbers 047 to 050 record that the parts box with the parts box serial number 2, the parts box with the parts box serial number 3, and the parts that were in the parts box with the parts box serial number 9 were mounted. ing. It is recorded that the vehicles with product serial numbers 051 to 060 are equipped with the parts box with the parts box serial number 2, the parts box with the parts box serial number 3, and the parts in the parts box with the parts box serial number 4. Is done. Vehicles with product serial numbers 061 to 075 are equipped with parts box serial number 4 parts box, parts box serial number 6 parts box B and parts box serial number 7 parts box. To be recorded. The vehicles from product serial number 076 to vehicle 85 are mounted with the parts box of the parts box serial number 5, the parts box of the parts box serial number 6, and the parts contained in the parts box of the parts box serial number 7. To be recorded. It is recorded that the vehicles with product serial numbers 086 to 100 are equipped with the parts box with the parts box serial number 9, the parts box with the parts box serial number 6, and the parts in the parts box with the parts box serial number 7. Is done. It is recorded that the vehicles with product serial numbers 101 to 120 are equipped with the parts box of the parts box serial number 10, the parts box of the parts box serial number 7, and the parts that were in the parts box of the parts box serial number 12. Is done. The product serial number 121 records that a component box with a component box serial number 10, a component box with a component box serial number 11, and a component that was in the component box with the component box serial number 12 are mounted.

  In this way, the product serial number of the vehicle and the part box serial number of the parts box in which the parts mounted on the vehicle are stored are recorded in the manufacturing history database. The part box serial number of the part box in which the part mounted on the vehicle is accommodated is known, and the part name and part lot number are known from the part box serial number. In addition, if the production lot number of a part is known, the part box serial number of the part box in which the part is stored can be known, and the product serial number of the vehicle on which the part is mounted can be identified from the part box serial number. it can.

  INDUSTRIAL APPLICABILITY The present invention is used in a production process for recording a product in a database by associating a part box serial number of a part box in which a part to be incorporated into the product is accommodated with a product serial number of the product.

It is a figure which shows the structure of the whole system with which the vehicle production system which concerns on this invention is applied. It is a block block diagram of a components acceptance / dispensing system. It is a block block diagram of a components information transmission system. It is a whole process flowchart of the vehicle production system which concerns on this invention. It is a flowchart which shows the procedure until components information transmission in a components maker. It is a processing flowchart in a parts reception department. It is a whole process flowchart of the vehicle production system which concerns on this invention. It is a schematic diagram which shows the flow of the operation | work using a vehicle production system. It is a table | surface which shows the number of production according to MTC. It is a table | surface which shows the required components according to MTC. It is a table | surface which shows required number of parts. It is a table | surface which shows the number of parts box accommodation for every part. It is a table | surface which shows a production order plan. It is a table | surface which shows a production process. It is a table | surface which shows the production process in the process with multiple types of components. It is a figure which shows the flow of the vehicle in a production line, and the serial number of a parts box.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Production factory 11 Production line 20 Vehicle production system 21 ALC system 21a Parts supply instruction part 22 Manufacturing history database 22a Parts box remaining number calculation part 23-1 Parts reception department 23-2 Parts reception department 23-3 Parts reception department 24 Assembly line Control device 25 Parts box delivery instruction section 26 Production planning system 27 Specification management system 28 Parts ordering system 29-1 Actual product slip issuing system 29-2 Current product slip issuing system 29-3 Actual product slip issuing system 54 Tag reader 60 Component information transmitting system 64 Parts information transmission device 65 Parts information reading storage device 100 Carry-in path 101 Parts delivery port 103-1,... 103-9 Parts box serial number reading transmission device 110 Automatic warehouse

Claims (9)

A product production system in which parts carry-in management means manages the carry-in of parts, the assembly line control means supplies the parts to the assembly line, assembles the product into a product, manufactures the product, and manages the association in a production history database. ,
The parts carry-in management means is
Attach a tag in which the part box serial number is recorded in the part box containing the part,
First transmission means for transmitting the component box serial number recorded in the tag and the component information contained in the component box to a manufacturing history database;
A second transmission means for reading the component box serial number recorded in the tag and transmitting it to the manufacturing history database, provided in the component assembly place of each step of the assembly line;
The manufacturing history database stores the parts box serial number read at the parts assembly place and transmitted by the second transmission means, and associates the parts box serial number with the product serial number of the product on the assembly line. Product production system characterized by memorizing and storing.   2. The product production system according to claim 1, wherein the first transmission means is provided on a part manufacturer side, and the manufacturing history database is provided on a product manufacturer side.   3. The product production system according to claim 1, wherein the part box serial number transmitted by the second transmission means is inquired in the manufacturing history database.   The manufacturing history database includes a component box remaining number calculation unit for calculating a remaining number of component boxes, and a component box leaving instruction for issuing a component box leaving instruction based on the remaining number of component boxes calculated by the component box remaining number calculating unit. 4. The product production system according to claim 2, further comprising means.   The product production system according to any one of claims 1 to 4, wherein a plurality of types of vehicles are assembled in the assembly line.   The product production system according to claim 1, wherein the tag is formed of an IC chip.   The product production system according to any one of claims 1 to 6, wherein the part information contained in the part box stored in the tag together with the part box serial number is manufacturing history information. A product production system in which parts carry-in management means manages the carry-in of parts, the assembly line control means supplies the parts to the assembly line, assembles the product into a product, manufactures the product, and manages the association in a production history database. ,
The parts carry-in management means is
Attach a tag in which the part box serial number is recorded in the part box containing the part,
First transmission means for transmitting the component box serial number recorded in the tag and the component information contained in the component box to a manufacturing history database;
An automatic warehouse for storing the delivered parts box;
A second transmission means for reading the component box serial number recorded in the tag and transmitting it to the manufacturing history database, provided in the component assembly place of each step of the assembly line;
The manufacturing history database stores the parts box serial number read at the parts assembly place and transmitted by the second transmission means, and associates the parts box serial number with the product serial number of the product on the assembly line. Product production system characterized by memorizing and storing.   The manufacturing history database includes a component box remaining number calculation unit for calculating a remaining number of component boxes, and issues a component box delivery instruction to the automatic warehouse based on the remaining number of component boxes calculated by the component box remaining number calculation unit. 9. The product production system according to claim 8, further comprising a parts box delivery instruction means.

Images