JP2007241509A - System for manufacturing elevator - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a system for manufacturing an elevator for efficiently manufacturing various elevator articles of different specifications by reducing loads of operators. <P>SOLUTION: Manufacturing plan data is prepared in consideration of a production capacity of a manufacturing line when manufacture is instructed (steps A11 and A12) to be started, and IC tags 38 for recording manufacturing plan data are issued per each component (step A13). Operation procedures of respective processes including processing operations of components are controlled according to the recorded manufacturing plan data so that the IC tag 38 is attached on each component of the elevator articles as a manufacturing target. Thus, loads of operators can be reduced, and various elevator articles of different specifications can be efficiently manufactured. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an elevator manufacturing system for manufacturing an elevator product such as a door product and a car product.

  In general, in an elevator production line, the work procedures in each process such as processing, painting, and assembly of parts that make up the elevator equipment from the production plan (scheduling) of the elevator goods ordered for each property are handled by the workers. It was decided by judgment. In this case, an efficient work procedure is determined based on the know-how of the worker, and the production plan is simply created on the schedule calculated backward from the delivery date.

  In addition, workers create machining data necessary for machining parts and select standard machining data. Further, the progress status of the manufacturing work is performed by the worker reading the management table with a bar code reader when the work in each process is completed.

On the other hand, for example, in a production line for automobiles and home appliances, a system for managing each component using an IC tag is known (see, for example, Patent Document 1).
JP 2003-295927 A

  As described above, conventionally, in an elevator production line, workers basically perform work procedures and management in each process from scheduling. For this reason, there are many human errors, and it is unclear how far the manufacturing work has progressed.

  On the other hand, for example, in a production line for automobiles and home appliances, a management system using an IC tag is known. However, this type of system is applied to a production line that mass-produces the same product with fixed specifications, and is effective for a production line that produces various products with different specifications such as elevators. Not right.

  The present invention has been made in view of the above points, and an object of the present invention is to provide an elevator manufacturing system that can reduce the burden on workers and efficiently manufacture elevator articles having different specifications. .

  The elevator manufacturing system of the present invention takes into consideration the equipment capacity of a manufacturing line, manufacturing plan creation means for creating manufacturing plan data of elevator articles ordered for each property, and manufacturing created by the manufacturing plan creation means IC tag issuing means for issuing an IC tag in which the plan data is recorded in parts, and the manufacturing plan data is obtained from the IC tag issued by the IC tag issuing means, and the elevator article is obtained based on the manufacturing plan data. And a control means for managing the work procedure of each process including the machining operation of the component to be constituted.

  According to the present invention, in response to a request from each customer, production plan data that takes into account the facility capacity of the production line is created even if the worker does not perform tasks such as scheduling. Furthermore, manufacturing operations including part processing operations are managed using an IC tag in which the manufacturing plan data is recorded. Thereby, the burden of a worker can be reduced and the elevator goods from which a specification differs can be manufactured efficiently.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a diagram showing an example of an elevator manufacturing process according to an embodiment of the present invention, and shows a general flow when an elevator car or the like is manufactured, for example.

  In the elevator production line, a processing step 11 for processing an elevator article such as a door article or a car article in units of parts (unit unit), a painting process 12 for painting the processed parts, and assembling the parts to be painted are assembled. Assembly process 13 for In these steps 11 to 13, equipment (machinery) corresponding to each process work is used. For example, in the processing step 11, various processing facilities such as a cutting machine for cutting a part into a specified size are used.

  FIG. 2 is a block diagram showing the overall configuration of the elevator manufacturing system according to the embodiment.

  The system includes a main computer 21. The main computer 21 is a general-purpose computer including a CPU, a ROM, a RAM, and the like. The main computer 21 includes various databases 41 to 46 to be described later, and performs control related to an elevator article manufacturing operation. The main computer 21 is connected to manufacturing systems 23a, 23b, and 23c corresponding to the respective processes via a network 22 such as a LAN (Local Area Network). The manufacturing systems 23a, 23b, and 23c perform manufacturing management of processes corresponding to the respective systems. In the example of FIG. 2, the manufacturing system 23 a corresponds to the processing step 11, the manufacturing system 2 ba corresponds to the painting step 12, and the manufacturing system 23 b corresponds to the assembly step 13.

Here, the detailed configuration of the manufacturing system 23a as a representative is shown in FIG.
The manufacturing system 23a includes a computer (PC) 31, an IC tag printer (PRT) 33, an IC tag reader / writer 34, an equipment 35, a tag sensor 36, and the like connected to the computer 31 via a system bus 32.

  The computer 31 is connected to the main computer 21 and the network 22 and controls each device in the system according to an instruction from the main computer 21. The IC tag printer 33 attaches to the management sheet 37 an IC tag 38 on which predetermined information relating to elevator production management is recorded and outputs the management information. Specific information recorded on the IC tag 38 will be described later. The management sheet 37 is a sheet on which a property name, a product name, and the like are printed, and is issued together with the IC tag 38.

  The IC tag reader / writer 34 reads information in the IC tag 38 issued by the IC tag printer 33 and writes information. The equipment 35 is machinery such as a cutting machine. The tag sensor 36 detects the IC tag 38 in a non-contact manner by a method such as electromagnetic induction.

  Note that the IC tag printer 33, the IC tag reader / writer 34, the equipment 35, and the tag sensor 36 are not limited to one, and are appropriately installed at a plurality of locations along the work path of the worker (see FIG. 11).

  The manufacturing systems 23b and 23c have basically the same configuration. However, since the IC tag 38 is basically required in the processing step 11 as the first step, the IC tag printer 33 is installed only in the manufacturing system 23a.

  Next, an elevator manufacturing method using an IC tag according to the present system will be described in detail.

  FIG. 4 is a diagram schematically showing the flow of the present system, showing the issue of an IC tag and the acquisition of information from the IC tag in the processing step.

(A) Issuing IC tags
When there is an elevator manufacturing start instruction (step A11), the main computer 21 of this system is ordered for each property with reference to the delivery date information database 41, the facility capacity / manufacturing man-hour database 42, and the component configuration database 43. Production plan data for elevator equipment is created (step A12).

  The delivery date information database 41 is a database that stores information related to the delivery date of each property. The equipment capacity / manufacturing man-hour master database 42 is a database that stores information on equipment capacity such as one-hour operating time of each equipment on the production line and processing man-hours of each product (see FIGS. 5 and 6). The parts configuration database 43 is a database that stores information related to parts that constitute an elevator article. Among these, the production plan data considering the equipment capacity of the production line is created by using the equipment capacity / manufacturing man-hour master database 42 in particular.

The production plan data creation process will be described in detail below.
FIG. 5 is a diagram showing an example of processing man-hour master data. In the figure, 51 indicates an elevator article, 52 indicates equipment, and 53 indicates a processing man-hour (processing time).

  There are “door products”, “car products” and the like as elevator products, and the number of processing steps is mastered for each of these products as shown in FIG. In this case, since the number of processing steps varies depending on the specifications of the same product, it is necessary to manufacture the product for each product with different specifications such as “door product 1”, “door product 2”, “door product 3”, etc. Are registered in the equipment capacity / processing man-hour master database 42 as master data of the processing man-hours.

  FIG. 6 is a diagram showing an example of equipment capacity master data. In the figure, 61 is equipment, 62 is operating time, and 63 is the number of equipment (number or number of people).

  The facility capacity (operation time, number of facilities) of the production line is mastered as shown in FIG. That is, in the production line, “processing machine 1”, “processing machine 2”, “processing machine 3”, “electrostatic coating”, “hand-blown coating”, “door assembly”, “car assembly” according to each process. "... is used. The daily operation time and the number of facilities (number or number of people) of these facilities are registered in the facility capacity / processing man-hour master database 42 as master data of the facility capacity.

  Here, the main computer 21 creates the production plan data for the elevator equipment requested for each property based on the processing man-hour master data in FIG. 5 and the equipment capacity master data in FIG. 6.

  In other words, for example, elevator products such as “door product 1” and “door product 2” are requested. In such a case, first, based on the processing man-hour master data of FIG. 5, the equipment and time required for manufacturing “door product 1” and “door product 2” are determined. Subsequently, based on the equipment capacity master data of FIG. 6, the equipment capacity of equipment necessary for the production of “door product 1” and “door product 2” is judged, and an optimal production plan so as not to exceed the equipment capacity Create data.

  FIG. 7 is a diagram illustrating an example of manufacturing plan data for each facility. In the figure, 71 indicates equipment, 72 indicates elevator equipment, and the length of one frame indicates work time. This production plan data indicates a schedule that can be worked in one day for each facility. In addition, when the work capacity of one day is exceeded, it will be sent to the work of the next day.

  FIG. 8 is a diagram showing an example of manufacturing plan data for each property. In the figure, 81 indicates an article (manufactured number) determined by the manufacturing process, 82 indicates an elevator article, and 83 indicates equipment. This manufacturing plan data describes the work procedure of each process necessary for manufacturing elevator equipment for each property, and is created based on the manufacturing plan data for each facility in FIG.

  For example, if there are “door product 1” and “door product 2” as property A, manufacturing plan data showing a work procedure that allows these products to be synchronized and efficiently operated in each process is created. . In the example of FIG. 8, each process is shown in units of one day. “Door article 1” is “processing machine 1” on the first day, “electrostatic coating” on the fourth day, The procedure is “door assembly”. “Door 2” is a procedure of “processing machine 1” on the first day, “processing machine 2” on the third day, “electrostatic coating” on the fourth day, and “door assembly” on the sixth day. It has become. In this case, the reason why the process does not proceed to the next process immediately after the end of one process is to match the start timing of other products using the same equipment.

  In addition, as shown in FIG. 9, when the manufacturing process is different for each floor of the building, manufacturing plan data that can be started at the same timing in the final assembly process is created (synchronization of manufacturing start). ). For supplies that need to be manufactured quickly, the manufacturing plan is rescheduled ahead of schedule. Rescheduling is also performed when remanufacturing is necessary due to manufacturing defects or specification changes.

  Returning to FIG. 4, the manufacturing plan data for each property created as described above is stored in the manufacturing plan database 44. Based on the manufacturing plan data stored in the manufacturing plan database 44, the main computer 21 first activates the IC tag printer 33 in the manufacturing system 23a and issues an IC tag 38 (step A13).

  At that time, as shown in FIG. 10, processing data, component configuration data, and manufacturing plan data are written in the IC tag 38. The processing data is data for processing a part according to specifications, and includes data such as size and shape, for example. This machining data is registered in the machining database 45. The part configuration data is data related to parts that constitute the elevator article, and is registered in the part configuration database 43. Further, the manufacturing plan data recorded in the IC tag 38 describes work procedures for each process for each property as shown in FIG.

(B) Information acquisition from IC tag
The IC tag 38 issued from the IC tag printer 33 is attached to a part constituting the elevator article to be manufactured. The method for attaching the IC tag 38 is not particularly limited. For example, a method may be used in which the IC tag 38 is attached to the management sheet 37 issued simultaneously from the IC tag printer 33 and attached to the carriage that carries the parts.

  Here, the main computer 21 reads the processing data recorded on the IC tag 38 through the IC tag reader / writer 34 in the manufacturing system 23a (step B11) and transfers it to the processing equipment 35 (step B12). . This makes it possible to easily process a part without an operator creating machining data.

  When the machining operation is completed, the processed parts are transferred to the next process according to the production plan data already recorded in the IC tag 38. The next transfer destination of the parts can be confirmed on the screen of the PC 31 by reading the production plan data of the IC tag 38 through the IC tag reader / writer 34.

  Further, at the time of transferring a part, the tag sensor 36 installed at each point of the production line detects the IC tag 38 attached to the part in a non-contact manner. Thereby, it can be checked where the parts have passed.

  When the machining operation is started, the start time is recorded on the IC tag 38 through the IC tag reader / writer 34. When the machining operation is completed, the completion time is recorded in the IC tag 38 through the IC tag reader / writer 34. The main computer 21 reads the start time and completion time recorded on the IC tag 38 through the IC tag reader / writer 34 (step B13), and transfers them to the manufacturing progress database 46 as progress information for storage (step B14). . Based on the progress information stored in the manufacturing progress database 46, it is possible to check the progress status of the elevator equipment being manufactured in real time. This progress information is also used for rescheduling the manufacturing plan.

  The same applies to other processes (painting process, assembly process). In the manufacturing systems 23b and 23c, work procedures in each process are managed in accordance with the manufacturing plan data recorded in the IC tag 38, and the start time and completion of the work are performed. Time is appropriately recorded on the IC tag 38.

  FIG. 11 is a diagram schematically showing an elevator production line.

  Now, two IC tag printers 33a and 33b are installed in a processing work area of an elevator production line (factory), and an IC tag reader / writer 34a, a door article processing machine 35a, an IC tag reader / writer 34b, and a car are provided in the vicinity thereof. It is assumed that an article processing machine 35b is installed. Further, it is assumed that an IC tag reader / writer 34c and a door assembly machine 35c, an IC tag reader / writer 34d, and a car assembly machine 35d are installed in the assembly work area. Here, the painting work area is omitted.

  Further, tag sensors 36a to 36f are arranged at respective predetermined locations along the work path of the worker, and the IC tag 38a attached to the part while the worker is transferring the part using a cart or the like. 38b is detected in a non-contact manner.

  In such a configuration, elevator goods (here, door goods and car goods) requested for each property are produced according to the production plan data shown in FIG. That is, for example, in the case of door products, first, the IC tag printer 33a automatically issues the IC tag 38a in parts (units). Processing data is recorded in advance in these IC tags 38a, which are transferred to a door article processing machine 35a by reading them through a nearby IC tag reader / writer 34a. Thereby, the processing machine 35a is driven and controlled, and the processing operation of the parts constituting the door article is started.

  The start time and completion time of the machining operation at this time are recorded in the IC tag 38a through the IC tag reader / writer 34a, and are also stored in the manufacturing progress database 46 as progress data as shown in FIG.

  FIG. 12 is a diagram showing an example of progress information stored in the manufacturing progress database 46, in which 91 is equipment, 92 is schedule data obtained from manufacturing plan data, and 93 is real-time for each operation in each process. The actual data obtained is shown. With this progress information, it is possible to confirm the progress of manufacturing the door article.

  Further, when the worker is moving a part with an IC tag, if detected by any of the tag sensors 36a to 36g, the position of the detected sensor is set as a passing position, and the main computer together with the passing time at that time. 21 is recorded in a memory (not shown). By displaying the recorded passing position and passing time on the display device of the main computer 21 as shown in FIG. 13, it is possible to confirm where the parts being transferred are passing.

  FIG. 13 is an arrangement screen diagram of the facilities 35a to 35d and the tag sensors 36a to 36g. When any of the tag sensors 36a to 36g detects the IC tag 38a or the IC tag 38b attached to the component being transferred, a mark corresponding to the sensor is lit and displayed, and the name, passing position, and time of the product that has passed through the mark are displayed. Displayed in a predetermined format.

  As described above, according to this system, the optimum production plan data that takes into account the facility capacity of the production line is automatically created for each request from each customer without the need for scheduling or other work. The elevator goods are manufactured according to the plan data. Therefore, the burden on the worker is greatly reduced, and it is possible to increase manufacturing efficiency by eliminating human error.

  In particular, in an elevator production line, a large number of identical products such as home appliances are not manufactured in large quantities, but various elevator products having different specifications must be produced on order. This system is effective for a production line that performs such a build-to-order production. Production plan data is created for each property according to the specifications of the elevator equipment. Yes.

  Further, in this system, since the machining data of the part is recorded on the IC tag, the machining work can be performed using the machining data. Therefore, there is no need for troublesome work such as the creation of machining data according to customer specifications as in the past, and simple and accurate machining operations simply by reading the machining data recorded on the IC tag. It can be performed.

  Further, in the present system, since the production plan data is recorded on the IC tag, it is possible to smoothly perform the work in each process according to the production plan data without the worker being particularly conscious.

  Also, in this system, the time at which the work in each process is started and completed is recorded as progress information on the IC tag, so that the current progress information can be obtained by reading the progress information during the manufacturing process. Can be confirmed.

  Further, in the present system, it is possible to confirm where the parts being transferred are passing by detecting the IC tag at each point of the production line in a non-contact manner.

  In the system configuration shown in FIG. 1, the manufacturing system is configured by dividing the processing step, the painting step, and the assembly step. However, the present invention is not limited to such a configuration. It may be configured to be performed by one manufacturing system.

  Further, the manufacturing process is not limited to the processing process, the painting process, and the assembly process, and may include other processes.

  In short, the present invention is not limited to the above-described embodiments as they are, and can be embodied by modifying the components without departing from the scope of the invention in the implementation stage. Moreover, various forms can be formed by appropriately combining a plurality of constituent elements disclosed in the embodiment. For example, some components may be omitted from all the components shown in the embodiment. Furthermore, constituent elements over different embodiments may be appropriately combined.

FIG. 1 is a diagram illustrating an example of an elevator manufacturing process according to an embodiment of the present invention. FIG. 2 is a block diagram showing the overall configuration of the elevator manufacturing system according to the embodiment. FIG. 3 is a block diagram showing a detailed configuration of the elevator manufacturing system according to the embodiment. FIG. 4 is a diagram schematically showing the flow of the elevator manufacturing system in the same embodiment. FIG. 5 is a diagram illustrating an example of processing man-hour master data of the elevator manufacturing system according to the embodiment. FIG. 5 is a diagram showing an example of equipment capacity master data of the elevator manufacturing system according to the embodiment. FIG. 7 is a diagram illustrating an example of production plan data for each facility of the elevator production system according to the embodiment. FIG. 8 is a diagram illustrating an example of manufacturing plan data for each property of the elevator manufacturing system according to the embodiment. FIG. 9 is a diagram for explaining the synchronization of the manufacturing start by the elevator manufacturing system according to the embodiment. FIG. 10 is a diagram for explaining data recorded in an IC tag of the elevator manufacturing system according to the embodiment. FIG. 11 is a diagram schematically showing an elevator production line in the embodiment. FIG. 12 is a diagram illustrating an example of progress information stored in a manufacturing progress database of the elevator manufacturing system according to the embodiment. FIG. 13 is an arrangement screen diagram of equipment and tag sensors of the elevator manufacturing system in the same embodiment.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Processing process, 12 ... Painting process, 13 ... Assembly process, 21 ... Main computer, 22 ... Network, 23a-23c ... Manufacturing system, 31 ... Computer (PC), 32 ... System bus, 33 ... IC tag printer (PRT) 34 ... IC tag reader / writer, 35 ... equipment, 36 ... tag sensor, 37 ... management sheet, 38 ... IC tag, 41 ... delivery date information database, 42 ... equipment capability / manufacturing man-hour master database, 43 ... part configuration database, 44 ... manufacturing plan database, 45 ... processing database, 46 ... manufacturing progress database, 51 ... elevator equipment, 52 ... equipment, 53 ... processing man-hour (processing time), 61 ... equipment, 62 ... operating time, 63 ... number of equipment (number or Number of persons), 71 ... Equipment, 72 ... Elevator equipment, 81 ... Property determined by the manufacturing process ( Ban), 82 ... elevators supplies, 83 ... facilities, 91 ... facilities, 92 ... schedule data obtained from the manufacturing planning data, 93 ... performance data obtained in real-time for each work in each process.

Claims (4)

Taking into account the equipment capacity of the production line, a production plan creation means for creating production plan data for elevator equipment ordered for each property,
IC tag issuing means for issuing an IC tag recording the production plan data created by the production plan creating means in units of parts;
Control means for acquiring the manufacturing plan data from the IC tag issued by the IC tag issuing means and managing the work procedure of each step including the processing work of the parts constituting the elevator article based on the manufacturing plan data; An elevator manufacturing system comprising: The IC tag includes processing data necessary for processing parts,
2. The elevator manufacturing system according to claim 1, wherein the control means drives and controls the processing equipment based on the processing data acquired from the IC tag. A recording means for appropriately recording the start time and completion time of work in each process of the production line on the IC tag,
The said control means acquires the start time and completion time of the work in each process recorded by the said recording means from the said IC tag, and manages this as progress information of the said elevator article, The elevator manufacturing system described. A detecting means for detecting the IC tag in a non-contact manner during the transfer of the part to which the IC tag is attached;
2. The elevator manufacturing system according to claim 1, wherein the control unit manages the position and time at which the IC tag is detected by the detection unit.

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