JP2008307644A - Assembly support system in different model concurrent production line - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To allow an assembly operator at each assembly station to easily change the contents of a component allocation table per bay at a production control device side corresponding to a component shelf in each assembly station without knowledge of complex information such as a bay code or a component code hardly accessed by the operator. <P>SOLUTION: A control means for a registration mode includes a detected bay information generating means for generating corresponding detected bay information based on a detection signal from a bay detector provided at each bay of the component shelf, a component information generating means for generating component information to be registered by reading a component information reader, and an informing means for informing a process management device of a table update request including the detected bay information generated by the detected bay information generating means and information of the component to be registered generated by the component information generating means. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention is different by flowing products in the middle of assembly of different models simultaneously to an assembly line in which a plurality of assembly stations are arranged in series, and performing assembly work for each model at each of the plurality of assembly stations. The present invention relates to an assembly support system applied to a simultaneous production line for different models, which enables simultaneous production of products of different models on the same assembly line.

  Nowadays, as a production line for industrial products (for example, automobiles, various electrical products, personal computers, etc.) suitable for high-mix low-volume production, different types of products in the middle of assembly are assembled in an assembly line in which a plurality of assembly stations are arranged in series. Different types of simultaneous production lines are known in which different types of products can be produced simultaneously on the same assembly line by flowing at the same time and performing assembly work for each model at each of these assembly stations.

  In these different models simultaneous assembly lines, parts shelves with parts pick-up guide indicators are used at each assembly station so that various types of assembly work can be carried out without error even by skilled workers. There are also those that employ an assembly support system (see, for example, Patent Document 1).

  In general, an assembly support system using a component shelf with this kind of component pick-up guide indicator will be described in detail later, but it will be described in detail below with reference to a “production process management device”, a “component shelf”, a “component shelf management device”, Is configured as follows.

  The production process management apparatus is composed of a computer system that collectively manages the assembly processes in all assembly stations included in the assembly line or a plurality of pre-assigned assembly stations, and is usually separated from the assembly line site. Installed in remote locations such as offices.

  The parts shelf is installed at each site of a plurality of assembly stations included in the assembly line, and has a plurality of entrances for accommodating parts necessary for assembly, and each of the plurality of entrances includes a frontage indicator. And a frontage detector.

  The parts shelf management device includes, for example, a programmable controller (PLC) and a programmable terminal (PT), and is installed at each site of a plurality of assembly stations included in the assembly line. Connected via communication network.

  As will be described in detail later, the production process management device includes a “higher-level receiving means”, “used part table storage means”, “part assignment table storage means”, “model / part / base conversion means”, , “Update operation means”, “part assignment table update means”, “production plan download means”, and “part assignment table download means”.

  The higher-level receiving means receives model-based production plan information including model information indicating each model (for example, a car model corresponding to a car production line) and production order information indicating the production order of the model. For example, data for 100 units is received via a predetermined network from a predetermined host device (for example, a core system that generates production plan information of the company).

  The used parts table storage means is composed of a storage device such as a hard disk, and for each of a plurality of assembly stations managed by itself, model information indicating each model and parts used in the assembly process of that model in the assembly station And a model-specific component table that is registered in association with each other.

  The component allocation table storage means is composed of a storage device such as a hard disk, and is assigned to the frontage information indicating the frontage of each of the parts shelves included in the assembly station and the frontage for each of the plurality of assembly stations managed by itself. A frontage component allocation table is stored which is registered in association with component information indicating components.

  The model / part / base conversion means refers to the model-based used parts table stored in the used parts table storage means, and receives the model-based production plan information received from the host device by the receiving means for each assembly station. To production plan information based on parts.

  The update operation means is constituted by a personal computer such as a notebook personal computer, and updates the registered contents of the frontage part assignment table stored in the part assignment table storage means by an operation on the process management server side.

  The component allocation table update means updates the contents of the frontage component allocation table stored in the component allocation table storage means based on the input frontage information and the part information input by the registration operation or the deletion operation of the update operation means. .

  The production plan download means downloads the part-based production plan information for each assembly station obtained from the model / part / base conversion means to the parts shelf management device of each assembly station.

  The component allocation table download means downloads the front-part-specific component allocation table updated by the component allocation table update unit to the component shelf management apparatus of the corresponding assembly station.

  In addition, the parts shelf management device of each assembly station includes “production plan storage means”, “part assignment table storage means”, and “control means for operation mode”, which will be described in detail later. Configured as follows.

  The production plan storage means is constituted by a storage device such as a hard disk, and stores part-based production plan information downloaded from the production process management device via the production plan download means.

  The component allocation table storage means is composed of a storage device such as a hard disk, and stores a front-end component allocation table downloaded from the production process management device via the component allocation table download means.

  The operation mode control means is stored in the production plan storage means in the parts shelf management apparatus by referring to the frontage part allocation table stored in the parts allocation table storage means in the parts shelf management apparatus. Based on the part-based production plan information, the use frontage information generating means for generating the frontage information indicating the frontage corresponding to the used parts for each assembly operation, the use frontage information generated by the use frontage information generation means, and the parts Frontage indicator control means for controlling the display operation of the frontage indicator corresponding to the used parts in each assembly operation based on the detection signal from the frontage detector of each frontage of the shelf is included.

  According to the assembly support system having the above-described configuration, the frontage indicators that store the parts required for assembly of the model are turned on in the parts shelf of each assembly station according to the order of the model to be assembled. Therefore, according to the lighting of the frontage indicator, it is possible to easily acquire the parts necessary for assembling each model by simply taking out the part from the frontage, and the assembly work of various models can be carried out without error even if it is not a skilled worker. There are advantages you can do.

In addition, a production process management device having an information conversion function or an information sorting function for each assembly station is interposed between the host device serving as the production plan information provider and the parts shelf management device of each assembly station. Therefore, the host device simply provides model-based production plan information including model information indicating each model (for example, a car model is equivalent in the case of an automobile production line) and production order information indicating the production order of the model. There is also an advantage that information suitable for control of the parts shelf is automatically provided to the parts shelf management device of each assembly station only by sending them out.
Japanese Patent Laid-Open No. 2003-40406

  In the parts shelf installed in each assembly station, which part is assigned to which front is an important factor that greatly affects the work efficiency during assembly work. Since the shape and size of each part, and the number of uses or frequency of use are different, the size and height of each frontage constituting the parts shelf, the distance from the worker, etc. are also different. In assigning each part to any frontage, each part must be assigned to the best frontage, taking into account the individuality of the parts and frontage.

  The part assignment for each frontage in the parts shelf is defined by the contents of the frontage-specific part assignment table stored in the production process management device. Therefore, the contents of the component allocation table must be appropriately defined in the component allocation operation.

  This part assignment work for each frontage is usually left to the person in charge of designing the production line, not the assembly worker at each assembly station. In other words, the production line designer recognizes the individuality of each part from the actual product, photos, catalogs, etc., and visits the assembly station to recognize the individuality of each frontage. In the terminal of a production management device (such as a laptop computer) installed at a remote location such as an office that is separated from the assembly station, specify each frontage and assign a part code corresponding to the part to be assigned to that frontage. By inputting, the contents of the frontage part allocation table stored in the production process management device are appropriately defined.

  By the way, no matter how the position of the assembly worker is taken into consideration, it is not always easy to perform a perfect parts assignment that will completely satisfy the assembly worker, based only on the concept of the production line designer. Absent. In addition, even if it is perfect at first, due to changes in the production frequency for each model, the frequency of use of parts housed in the easy-to-take out doors decreases, or conversely, it is housed in the hard-to-take out doors. The usage frequency of the parts to be used may increase, resulting in an unusable part assignment. In such a case, on the side of the assembly operator at each assembly station, the parts are exchanged between the two frontages, or the parts accommodated in either frontage are replaced with another empty frontage, etc. Needless to say, it is convenient if the component assignment can be easily changed.

  However, in the conventional assembly support system, in order to change the contents of the part allocation table by frontage, the terminal of a production management apparatus (in a remote place such as an office separated from the assembly line site ( Since it is necessary to operate a notebook type personal computer, etc., the person in charge of assembly at each assembly station must leave the work site and go to the terminal of the production management device each time, and it cannot endure the trouble.

  Also, even if there is a terminal similar to the operation terminal of the production management device at each assembly station, the assembly worker at each assembly station must use the frontage code and part code necessary for the change operation of the frontage part allocation table. Since there is no opportunity to get in touch with each other, even if such a terminal is familiar, it is inconvenient and practically useless.

  The present invention has been made paying attention to such conventional problems, and the object of the present invention is to correspond to the parts shelf in each assembly station on the side of the assembly operator in each assembly station. Applying the contents of the part allocation table by frontage on the production management device side to a heterogeneous simultaneous production line that can be easily changed without knowing complicated information that is usually difficult for an assembly worker such as frontage codes and part codes. An assembly support system is provided.

  Other objects and operational effects of the present invention will be easily understood by those skilled in the art by referring to the following description of the specification.

  The above technical problem can be solved by an assembly support system applied to a heterogeneous simultaneous production line having the following configuration.

  That is, this assembly support system allows different types of products in the middle of assembly to flow simultaneously on an assembly line in which a plurality of assembly stations are arranged in series, and performs assembly work for each model at each of the plurality of assembly stations. Thus, the assembly support system is applied to a different model simultaneous production line that enables different types of products to be produced simultaneously on the same assembly line.

  As will be described in detail later, this assembly support system includes a “production process management device”, a “component shelf”, and a “component shelf management device”.

  The production process management apparatus collectively manages the assembly processes in all assembly stations or a plurality of pre-assigned assembly stations included in the assembly line, and is a remote place such as an office separated from the assembly line site. Installed.

  The parts shelf is installed at each site of a plurality of assembly stations included in the assembly line, and has a plurality of openings for accommodating parts necessary for assembly, and each of the plurality of openings includes a front opening. A display and a frontage detector are provided.

  The parts shelf management device is installed at each site of a plurality of assembly stations included in the assembly line, and is connected to the production process management device via a communication network.

  In addition, the production process management apparatus includes “upper side receiving means”, “used part table storage means”, “part assignment table storage means”, “model / part / base conversion means”, and “update operation”. Means ”,“ first component allocation table update unit ”,“ second component allocation table update unit ”,“ production plan download unit ”, and“ component allocation table download unit ”.

  The higher-level receiving means receives model-based production plan information including model information indicating each model and production order information indicating the production order of the model for a predetermined number of production units from a predetermined higher-level device.

  The used parts table storage means associates, for each of a plurality of assembly stations managed by itself, model information indicating each model and part information indicating parts used in the assembly process of that model in the assembly station. The registered model-specific component table is stored.

  The component assignment table storage means associates, for each of a plurality of assembly stations managed by itself, the frontage information indicating each frontage of the parts shelf included in the assembly station and the part information indicating the parts assigned to the frontage. The front-part component allocation table is registered.

  The model / part / base conversion means refers to the model-based used part table stored in the used part table storage means, and receives the model-based production plan information received from the host device by the receiving means for each assembly station. Convert to production plan information based on each part.

  The update operation means updates the registered content of the frontage part assignment table stored in the part assignment table storage means by an operation on the process management server side.

  The first component allocation table updating means includes a front-end component allocation table stored in the component allocation table storage means based on input frontage information and part information input by a registration operation or a deletion operation of the update operation means. Update the contents.

  The second component allocation table updating means includes a part allocation table stored in the component allocation table storage means based on the detection window information and the component information included in the table update request notified from the component shelf management apparatus. Update the contents of.

  The production plan download means downloads the part-based production plan information for each assembly station obtained from the model / part / base conversion means to the parts shelf management device of each assembly station.

  The component allocation table download means downloads the front-part component allocation table updated by the first and second component allocation table update units to the component shelf management apparatus of the corresponding assembly station.

  Further, the parts shelf management device of each assembly station will be described in detail later, but “production plan storage means”, “part assignment table storage means”, “part information reader”, and “mode setting means”. And “control means for operation mode” and “control means for registration mode”.

  The production plan storage means stores part-based production plan information downloaded from the production process management device via the production plan download means.

  The part assignment table storage means stores a frontage part assignment table downloaded from the production process management device via the part assignment table download means.

  The component information reader can read the recorded component information using a machine-readable code.

  The mode setting means can set the operation mode to at least an operation mode and a registration mode.

  As will be described in detail later, the operation mode control means includes a “frontage information generation means” and a “frontage display control means”.

  The use frontage information generating means refers to the parts stored in the production plan storage means in the parts shelf management apparatus by referring to the frontage part assignment table stored in the parts assignment table storage means in the parts shelf management apparatus. Based on the production plan information of the base, use frontage information indicating a frontage corresponding to the used parts for each assembly operation is generated.

  The frontage display control means is configured to use the frontage information corresponding to the frontage corresponding to the used parts in each assembly operation based on the frontage usage information generated by the frontage front information generating means and the detection signal from each frontage frontage detector of the parts shelf. Controls the display operation of the frontage display.

  As will be described in detail later, the registration mode control means includes “detection edge information generation means”, “part information generation means”, and “notification means”.

  The detection frontage information generating unit generates corresponding detection frontage information based on a detection signal from a frontage detector provided at each frontage of the component shelf.

  The component information generation means generates component information to be registered by a reading operation of the component information reader.

  The notifying means notifies the process management apparatus of a table update request including the detection front edge information generated by the detection front edge information generating means and the registration target part information generated by the part information generating means.

  According to such a configuration, in the parts shelf management device of each assembly station, the operation mode is set to the registration mode, and if the frontage detector and the part information reader are operated in the set state, the detection is performed. By the action of the frontage information generating means, corresponding detection frontage information is generated based on the detection signal from the frontage detector provided at each frontage of the parts shelf, and the part information generating means is used to Part information to be registered is generated by the reading operation of the information reader, and further, the detection front information generated by the detection front information generation unit and the registration target generated by the part information generation unit by the action of the notification unit A table update request including component information is notified to the process management apparatus.

  Then, on the side of the production process management device, the component based on the detection frontage information and the component information included in the table update request notified from the component shelf management device by the action of the second component allocation table update means. The contents of the frontage part allocation table stored in the allocation table storage means are updated.

  Therefore, according to the present invention, in the parts shelf management device of each assembly station, the operation mode is set to the registration mode, and in the setting state, by operating the frontage detector and the part information reader, The contents of the part allocation table stored in the frontage table stored in the part allocation table storage means on the production process management device side can be remotely updated, and on the assembly operator side in each assembly station, it corresponds to the parts shelf in each assembly station The contents of the part allocation table classified by frontage that are to be produced can be easily changed without knowing complicated information that is usually difficult for an assembly operator such as frontage code or part code.

  In the above-described assembly support system, in the preferred embodiment, the production process management device and the parts shelf management device of each assembly station may be configured as follows.

  That is, in the production process management apparatus, the production plan download means converts the part-based production plan information for each assembly station obtained from the model / part / base conversion means to the parts shelf management apparatus of each assembly station. The system is designed to download only the specified number of units.

  Further, in the parts shelf management device of each assembly station, the production plan storage means in the parts shelf management device stores part-based production plan information downloaded from the production process management device via the production plan download means. It has a storage capacity that can be stored together for a predetermined number of production units.

  Further, in the control means for the normal mode, the frontage display control means sequentially squeezes out from the frontage-based production plan information for a predetermined number of production units stored in the production plan storage means in the parts shelf management device. The frontage corresponding to the parts required for the assembly work of each production model based on the frontage information corresponding to the frontage used for each unit and the detection signal from the frontage detector of each frontage of the parts shelf It is designed to control the display operation of the display.

  Furthermore, in the control means for the registration mode, the frontage information generating means refers to the contents of the updated frontage part allocation table downloaded and stored in the part allocation table storage means in the parts shelf management device. Thus, the parts-based production plan information for a predetermined number of productions stored in the production plan storage means in the parts shelf management device is reconverted into frontage-based production plan information.

  According to such a configuration, in the parts shelf management device of each assembly station, each production is based on the production plan information for a predetermined number of production units downloaded in advance from the production process management device via the production plan download means. Since the display operation of the frontage display corresponding to the frontage corresponding to the parts required for the assembly work of the model is controlled, even if a situation where the download is temporarily disabled due to a network error etc. occurs, While there is an advantage that assembly work in the production line does not stop immediately, in the registration mode, when the updated frontage part allocation table is downloaded from the production process management apparatus side, the production in the parts shelf management apparatus is performed. The part-based production plan information for the predetermined number of productions stored in the plan storage means is the updated part-by-part parts allocation table. By referring to the contents of the schedule, it is automatically reconverted into frontage-based production plan information, so the already downloaded production plan is automatically regenerated to the one corresponding to the new frontage part allocation table. Is done.

  At this time, the production process management device includes a part master storage means for storing a part master formed by registering part information relating to all parts usable at each assembly station on the production line, and The second component allocation table update unit collates the registration target component information included in the table update request notified from the component shelf management device with the component master stored in the component master storage unit, The contents of the part allocation table by frontage may be updated while the contents of the part allocation table by frontage are not updated when there is a mismatch.

  According to such a configuration, when the part desired to be used at each assembly station is an unapproved part, the contents of the frontage part allocation table on the production process management device side are not updated. While permitting the update of the frontage part allocation table from the beginning, it is possible to avoid the risk that an unapproved part is used without permission and the assembly work is performed.

  In the series of inventions described above, in the parts shelf management apparatus, the registration mode control means is based on the contents of the frontage parts assignment table stored in the parts assignment table storage means in the parts shelf management apparatus. Further, a registerable frontage guide means for searching a frontage to which no part is assigned and operating a frontage display corresponding to the searched frontage in a predetermined display mode may be included.

  According to such a configuration, even if any of the front doors is empty in the parts shelf, the reason is that the parts are not assigned, or the parts are used up by chance and waiting for replenishment. It is possible for the worker to grasp at a glance whether the current state is in the state, and the worker can immediately find a frontage where new parts can be assigned.

  Similarly, in the series of inventions described above, in the parts shelf management apparatus of each assembly station, the mode setting means can be set to the deletion mode in addition to the operation mode and the registration mode, and Control means for the deletion mode may be provided.

  At this time, the control means for the deletion mode guides the part information that is a deletion candidate based on the frontage usage status information in the frontage part allocation table stored in the part allocation table storage means in the parts shelf management device. A deletion candidate guidance display means for displaying, a deletion target selection means for selecting desired part information from the part information as a deletion candidate guided and displayed by the deletion candidate guidance display means, and a deletion target selection means. Notification means for notifying the production process management apparatus of an update request including part information selected as a deletion target and frontage information.

  According to such a configuration, when the deletion mode is set, the component information that becomes the deletion candidate based on the frontage usage status information in the frontage component allocation table stored in the component allocation table storage means in the component shelf management apparatus Is displayed, the update request including the selected part information and the frontage information is notified to the production process management device only by performing an operation of selecting the desired part information from the information. This part information can be deleted from the frontage part assignment table on the production process management device side.

  In the above series of inventions, the frontage detector may be a switch that is provided on a part removal side surface or a part supply side surface of each frontage and that is manually operated. It may be a photoelectric sensor that is provided on the side surface or the component supply side surface and that operates when an object enters the frontage. In the series of inventions described above, the frontage indicator may be a display lamp provided on a part take-out side surface or a part replenishment side surface of each frontage.

  According to such a configuration, these switches, photoelectric sensors, and indicator lamps are originally attached to the parts shelf with this kind of take-out guide function. Therefore, there is an advantage that does not bring a special cost increase.

  In the above series of inventions, the component information reader may be an optical code reader, a magnetic code reader, or an RFID tag reader capable of reading a one-dimensional or two-dimensional optical code displayed on a component storage box or the like. Good.

  According to such a configuration, when storing the parts with the parts box in each front of the parts shelf, the one-dimensional or two-dimensional parts are displayed on the side of the parts box or the separately prepared parts information list display sheet. If component information is attached using an optical code, magnetic code, RFID tag, etc., it is a complex information that is difficult for an assembly operator to contact, such as a component code, simply by performing a reading operation using a component information reader. Even without knowing, it is possible to easily input component information.

  Further, in the series of inventions described above, the parts shelf management device is composed of a programmable controller that functions as a client body and a programmable terminal that functions as a human machine interface, and constitutes the parts shelf management device. Each function of the storage means, the parts allocation table storage means, the control means for the operation mode, and the control means for the registration mode is realized by the user program of the programmable controller and constitutes the parts shelf management device. If the function of the setting means is realized by the programmable terminal, the present invention can be easily realized without using a special dedicated control device.

  According to the present invention, on the side of the assembly operator at each assembly station, the contents of the part allocation table by frontage corresponding to the parts shelf at each assembly station are referred to as frontage codes and part codes. It is possible to provide an assembly support system applied to a heterogeneous simultaneous production line that can be easily changed without knowing complicated information that is usually difficult for an assembly operator to contact.

  Hereinafter, a preferred embodiment of an assembly support system according to the present invention will be described in detail with reference to the accompanying drawings.

  As described above, the heterogeneous simultaneous production line to which the assembly support system according to the present invention is applied is configured to simultaneously flow products in the middle of assembly of different models to an assembly line in which a plurality of assembly stations are arranged in series. In each of the plurality of assembly stations, different types of products can be simultaneously produced on the same assembly line by performing assembly work for each model.

  This heterogeneous simultaneous production line can be applied to various industrial products such as automobiles, home appliances, computers, various electronic devices, etc. The total length is 10m to several such as electronic device manufacturing lines It varies from a small one of 10 m to a large one of several hundred meters or more such as an automobile production line.

  In addition, the “assembly line consisting of a plurality of assembly stations arranged in series” referred to here has a plurality of assembly stations arranged along one continuous transfer line, and any products that are being assembled are stopped. Without passing through each assembly station (continuous transfer type) and the assembly stations that follow each other are connected by an independent transfer line. At each assembly station, products in the middle of assembly are transferred from the upstream transfer line. After receiving, both the one that executes the determined assembly work in the stationary state, and sends the intermediate assembly product after completion of the assembly work to the downstream transfer line (intermittent transfer type) is included. .

  Furthermore, in a continuous conveyance type assembly line, an assembly operator is placed at each assembly station, and a predetermined assembly operation is performed on a product being assembled while passing in front of each assembly station (work) A person stationary type) and a person who carries an assembly worker on a transportation line and performs a predetermined assembly work while flowing in a certain transportation section together with the product in the middle of assembly (worker movement type).

  A layout diagram showing an example of a heterogeneous simultaneous production line is shown in FIG. The illustrated heterogeneous simultaneous production line is configured as an automobile production line, and corresponds to the above-described continuous conveyance type and worker movement type.

  As shown in the figure, the assembly line 1 is composed of a single continuous transport belt 10 having a function of transporting products in the middle of an automobile assembly. A plurality of assembly stations are arranged at an appropriate longitudinal distance from each other. In this example, only two adjacent assembly stations among the plurality of assembly stations, that is, the (N) th assembly station and the (N + 1) th assembly station are shown. Moreover, the code | symbol 13 is the multiple transport vehicle for conveying the components which should be replenished.

  The conveyance band 10 is divided into equal intervals in the traveling direction, and a plurality of partitioned areas 10a, 10a,. In each of the partition areas 10a, 10a,..., A car partly assembled product 11 and a single assembly worker 12 responsible for assembling the partly assembled product are placed.

  Each of the assembly stations (for example, the (N) assembly station and the (N + 1) assembly station) has a component shelf 2 with a component extraction guide function and a component shelf management for managing the component shelf, which will be described in detail later. A device 3 is arranged.

  An explanatory diagram (part 1) showing an example of the parts shelf is shown in FIG. 7, and the part (part 2) is shown in FIG. In these explanatory views, the parts shelf 2 is viewed from the back side (parts supply side). As is clear from these drawings, the parts shelf 2 has a plurality of openings (meaning parts storing parts) 21. In the figure, each frontage 21 has the same shape and is arranged vertically and horizontally, but in reality, the shape and arrangement of each frontage 21 are various, and are vertically long, horizontally long, and tall. There are also parts shelves in which low items and the like are mixed.

  As a structural material for forming the frontage 21, pipe materials are generally used as shown in FIGS. 19 and 20 when handling automobile parts. Each frontage 21 has a component extraction opening facing the assembly line 1 and a component supply opening located on the opposite side. Depending on the component shelf, the bottom plate of each front opening 21 is an inclined surface that descends from the component supply opening toward the component extraction opening. Preferably, rolling rollers and rolling steel balls are arranged on the inclined surface. Has been.

  The parts to be accommodated in each frontage 21 are accommodated directly in a disassembled state as they are for large parts, whereas, for relatively small and regular parts, for example, FIG. 20 and FIG. As shown in FIG. 5, a certain number of parts boxes 5 are accommodated together.

  As will be described in detail later, each component box 5 is affixed with a label 51 in which component-related information relating to the component housed in the component box is displayed as a barcode. Here, examples of the component-related information displayed on the label 51 as a barcode include the component name of the component, the component identification code, the number of units accommodated per box, the manufacturer code, and the date of manufacture.

  When the parts box 5 supplied from the parts replenishment opening of each frontage 21 has an inclined bottom surface, it is guided by the rolling rollers and rolling steel balls arranged on the inclined bottom surface of each frontage 21 to supply the parts. It moves under its own weight from the opening side to the part extraction opening side. As a result, the parts box 5 moves by its own weight in the frontage 21 and is set to a predetermined position near the opening where the parts can be easily taken out.

  In the parts shelf 5, a frontage indicator 22 and a frontage detector 23 are attached to a part extraction opening of each frontage 21 or a part extraction opening and a component supply opening of each frontage 21. The frontage indicator 22 and frontage detector 23 attached to the part extraction opening are mainly used to guide the part extraction frontage (in the case of the frontage display 22) and to confirm that the part has been removed (in the case of the frontage detector). Served for. On the other hand, the frontage indicator 22 and the frontage detector 23 attached to the parts replenishment opening provide guidance for replenishing parts (in the case of the frontage display 22) and confirmation that the parts have been replenished (frontage detector). In case of). In the example of FIG. 2, the frontage display 22 is turned on / off by the output of the OUT slave 24 of the PLC 31, and the input signal from the frontage detector 23 is taken into the PLC via the IN slave 25.

  As specific structures of the frontage display 22 and the frontage detector 23, various forms can be employed. In the case of the parts shelf shown in FIG. 7, a display lamp 22 a is employed as the frontage indicator 22, and a lever switch 23 a is employed as the frontage detector 23. On the other hand, in the example of FIG. 8, a display lamp 22 b is employed as the frontage indicator 22, and a multi-optical axis photoelectric sensor 23 b is employed as the frontage detector 23. As will be described later in detail, a frontage indicator 22 and a frontage detector 23 attached to the part replenishment opening are used for the part registration operation which is a main part of the present invention.

  7 and 8, reference numeral 32 denotes a programmable terminal (PT) that functions as an operation unit of the parts shelf management device 3 described later, and reference numeral 34 denotes various warnings for an assembly worker around the parts shelf. It is a warning light to give.

  Next, an overall configuration diagram of an assembly support system according to the present invention is shown in FIG. As shown in the figure, this assembly support system includes a production process management device 4, a component shelf 2, and a component shelf management device 3, which will be described in detail later.

  The production process management device 4 collectively manages the assembly processes in all the assembly stations included in the assembly line 1 or a plurality of pre-assigned assembly stations. The production process management apparatus 4 is remote from an office or the like separated from the site of the assembly line 1. It is installed at the place.

  The parts shelf 2 is installed at each site of a plurality of assembly stations included in the assembly line 1, and has a plurality of openings 21 for accommodating parts necessary for assembly, and each of the plurality of openings 21 includes As described above with reference to FIGS. 7 and 8, the frontage display 22 and the frontage detector 23 are provided.

  As described above with reference to FIG. 1, the parts shelf management device 3 is installed at each site of a plurality of assembly stations included in the assembly line 1 and is connected to the production process management device 4 and a communication network (NET 2). Is tied through.

  Hereinafter, the hardware configuration and the software configuration of each of the production process management device 4, the component shelf management device 3, and the component shelf 2 will be described in more detail.

  First, the production process management device 4 will be described. As shown in FIG. 2, the production process management device 4 is composed of a plurality of computers including a server, and the storage means (M1), which will be described later, is stored in a storage means such as a hard disk. ), Storage means (M2) for storing model-based production plan information (INFO12), storage means (M3) for storing production plan information (INFO21) based on used parts, and used part table (TB1) At least storage means (M4) for storing and storage means (M5) for storing the component allocation table (TB21) are provided.

  A flowchart showing the basic processing of the production process management device 4 is shown in FIG. In the figure, when processing is started, first, in step 1101, model-based production plan information (INFO11) is received from the host device 100, and model-based production plan information (INFO12) is stored in the storage means (M2). Is stored (upper receiving means).

  A block diagram of the host device 100 is shown in FIG. As shown in the figure, the host device 100 and the production process management device 4 are connected by a network (NET1). In the storage means (M0) such as a hard disk of the host device 100, as shown in the figure, model information (model 1, model 1, model 5... Model-based production plan information (INFO 11) including model 3) and production order information (1, 2, 3,... N) indicating the production order of the model is stored.

  In the processing of step 1101, this model-based production plan information (INFO11) is transmitted from the host device 100 to the production process management device 4 via the network (NET1). Is stored as model-based production plan information (INFO12) in the storage means (M2).

  Returning to FIG. 11, in the subsequent step 1102, the model-based production plan information (INFO 12) is read from the storage means (M 2), and the model-based parts table (TB 1) stored in the storage means (M 4). , The process (model / part / base conversion means) for converting into production plan information (INFO 21) based on the used parts for each assembly station and storing it in the storage means (M3) is executed.

  FIG. 4 shows an explanatory diagram showing the contents of the model-specific used parts table (TB1) for each assembly station, and FIG. 5 shows production plan information (INFO 21) based on used parts for each assembly station. As shown in FIG. 4, the storage means (M4) indicates each model for each of a plurality of assembly stations (assembly station 1, assembly station 2, assembly station 3,...) Managed by itself. Model information (model 1, model 2, model 3,...) And part information (part 1, component 2,..., N) indicating parts used in the assembly process of that model at the assembly station. A model-specific component table (TB1) that is registered in association with each other is stored. In the example shown in the figure, for the assembly station 1, in the case of the model 1, the part 1 is used (O), the part 2 is not used, and the part n is used (O). In the case of the model 2, the part 1 is not used, the part 2 is used (◯), and the part n is used (◯).

  Then, in the processing of step 1102, the models (model 1, model 2, model 3,...) In each order included in the model-based production plan information (INFO 12) similar to that shown in FIG. By referring to the model-specific used parts table (TB1) shown in FIG. 4, the model-based production plan information (INFO 12) is used to produce the used parts-based production for each assembly station as shown in FIG. The plan information (INFO 21) is converted and stored in the storage means (M3).

  Returning to FIG. 11, in the following step 1103, the production plan information (INFO 21) based on the used parts for each assembly station is read out from the storage means (M 3), and this is corresponding to each corresponding via the network (NET 2). PLC (..., 31 (N−1), 31 (N), 31 (N + 1) constituting the parts shelf management device 3 of the assembly station (..., N−1, N, N + 1,...) ,...) Is downloaded (production plan download means). As will be described later, the used part-based production plan information (INFO 21) downloaded in this manner is stored in the memory of each corresponding PLC (31 (N−1), 31 (N), 31 (N + 1),...). Is stored in the storage means (M6) provided as the production plan information (INFO 22) based on the used parts.

  Next, the parts shelf management device 3 will be described. In the example of FIG. 2, the parts shelf management device 3 of each assembly station is a programmable controller (PLC) (..., 31 (N−1), 31 (N), 31 that performs a central function of control. (N + 1),..., And programmable terminals (PT) (..., 32 (N−1), 32 (N), 32 (N + 1),. Bar code readers (..., 33 (N-1), 33 (N), which function as a component information reader 33 that can read component information recorded using machine-readable codes. 33 (N + 1),...).

  Each PLC (..., 31 (N−1), 31 (N), 31 (N + 1),...) Is downloaded from the production process management device 4 via the production plan download means. Production plan storage means (M6) (see FIG. 5) for storing the part-based production plan information (INFO 21) to be stored, and the parted parts downloaded from the production process management device 4 via the part assignment table download means Component allocation table storage means (M7) (see FIG. 9) for storing the allocation table (TB21) is provided.

  Furthermore, each function (mode setting means, operation mode control means, registration mode control means, and deletion mode control means) of the parts shelf management apparatus 3 to be described later is realized by incorporating a predetermined user program into the PLC 31. Yes.

  FIG. 13 is a general flowchart showing the entire processing of the PLC 31 constituting the parts shelf management apparatus 3, FIG. 14 is a flowchart showing the mode setting process of the apparatus, and FIG. 18 is a diagram showing a display example of the programmable terminal (PT). Respectively.

  When the programmable terminal (PT) 32 constituting the parts shelf management device 3 is activated, although not shown, an “operation mode” button, a “registration mode” button, and a “delete mode” button are displayed on the touch screen. Is displayed. When one of these buttons is touched in this state, the mode setting process shown in FIG. 14 is executed by interruption. This mode setting process functions as a mode setting means capable of setting the operation mode to at least “operation mode”, “registration mode”, and “deletion mode”.

  In FIG. 14, when processing is started, first, after inputting a touch input (step 1401), depending on whether the content is “operation mode”, “registration mode” or “deletion mode” (steps 1402 and 1404). , 1406), setting process to the operation mode (step 1403), setting process to the registration mode (step 1405), and setting process to the deletion mode (step 1407) are executed.

  On the other hand, in the general flowchart of FIG. 13, in step 1301, the production plan information (INFO 21) based on the used parts is downloaded from the production process management device 4 for a predetermined number of production units (for example, 100 units). The production plan information for the predetermined number of productions downloaded in this way is stored in the storage means (M6) as production part-based production plan information (INFO 22).

  Subsequently, depending on whether the operation mode is “operation mode”, “registration mode”, or “deletion mode”, operation mode processing (step 1303), registration mode processing (step 1305), deletion mode processing (step 1307) Are selectively executed, and thereafter, the above processing (steps 1303, 1305, 1307) is repeatedly executed until a predetermined end command is given (step 1308).

  A flowchart showing details of the operation mode processing is shown in FIG. In the figure, when the processing is started, first, by referring to the frontage component allocation table (TB22) (see FIG. 9) stored in the component allocation table storage means (M7) by steps 1501 and 1502, Use frontage information indicating the frontage corresponding to each used part for each assembly operation based on the part-based production plan information (INFO22) (see FIG. 5) stored in the production plan storage means (M6) in the parts shelf management device 3 Processing for generating (INFO 31) (refer to FIG. 10) (usage information generating means) is executed.

  The contents of the parts-based production plan information (INFO 22) stored in the production plan storage means (M6) are shown in FIG. As shown in the figure, in this example, the parts-based production plan information (INFO 22) is configured by storing a model of each production order and a series of used parts of the model in association with each other. Has been. Further, FIG. 9 shows the contents of the frontage component allocation table (TB22) stored in the component allocation table storage means (M7). As shown in the figure, the frontage-specific component allocation table (TB22) stores, in this example, each frontage number (frontage code) and the frontage assigned component (part code) in association with each other. It is comprised by. Further, frontage information (INFO 31) corresponding to the used parts for each production model is shown in FIG. As shown in the figure, the frontage information (INFO31) corresponding to the used parts for each production model is, in this example, the frontage number (frontage code corresponding to a series of used parts of the model in each production order and the model in each production order. ) Are stored in association with each other.

  In step 1501, a series of used part codes corresponding to the production order at that time is read from the production plan information (INFO 22) shown in FIG. 5, and in the subsequent step 1502, the frontage classification shown in FIG. By referring to the used part allocation table (TB22), a series of frontage numbers (frontage codes) are generated from the read series of used part codes.

  In subsequent steps 1503 to 1507, a series of frontage numbers (frontage codes) which are used frontage information generated by the above-mentioned use frontage information generating means (steps 1501 and 1502), and the front side opening of each frontage 21 of the parts shelf 2. Based on the detection signal from the frontage detector 23, a process (frontage display control means) for controlling the display operation of the frontage opening 22 on the front side opening of the part to be used in each assembly operation is executed.

  That is, in step 1503, by executing the display processing of the corresponding frontage indicator, the frontage opening 22 on the front side of the frontage corresponding to a series of frontage numbers (frontage codes) is turned on, and the assembly operator is informed. On the other hand, the removal of the component is instructed, and in this state, the operation of the front opening opening detector 23 is awaited (NO in step 1504). In this state, when the assembly operator removes a part from any of the frontage, the detector is determined to be activated (YES in step 1504). Subsequently, the activated detector is the frontage detector instructed to take out the part. If it is determined whether or not there is a frontage detector other than that (step 1505 NO), predetermined error processing is executed (step 1506), for example, a warning lamp 34 (see FIGS. 7 and 8). ) Is turned on, but if it is a detector of the corresponding frontage (step 1505 YES), the above-described series of processing (steps 1503 to 1505) continues until the parts removal from all designated frontage is completed (NO in step 1507) ,Repeated. This operation mode processing (steps 1501 to 1507) is repeated for all models constituting the production plan information (INFO 22).

  As described above, in the operation mode of the parts shelf management device 3, as long as the model-based production plan information (INFO 11) is sent from the host device 100 side, the parts shelf of each assembly station is obtained by the operation of the production process management device 4. Since each of the management devices 3 can automatically acquire the parts-based production plan information (INFO 22) and the front-part-specific component allocation table (TB 22), each of the component shelf management devices 3 of the respective assembly stations is thereafter acquired. As a result, parts necessary for the assembly work of each model are instructed to the assembly worker, and the assembly work can be carried out without error even without a skilled worker.

  Next, in the parts shelf, the part assignment update work such as deleting a part assignment for a certain frontage, changing a part assignment from one frontage to another, or assigning a part in an empty frontage. Will be described.

  In the assembly support system in this example, it is possible to update the parts assignment table for such part assignment change or deletion both by the operation on the production process management device side and the operation on the parts shelf management device side. It is said. Here, the operation on the production process management apparatus side is a function that has been provided in this type of assembly support system, and the operation on the parts shelf management apparatus side is newly provided in this application. Function.

  First, the update process of the component allocation table by the operation on the production process management apparatus side will be described first. When the component allocation is updated by the operation of the production process management device 4, a registration operation or a deletion operation is performed at a terminal (such as a notebook computer) provided in the production process management device 4. As described above, the production process management device 4 is installed in a remote place such as an office separated from the site of the assembly line 1.

  In this example, in order to change a registered part to another part for a frontage where some part is registered, first, a deletion request operation for deleting the registered part must be performed. . The deletion request operation includes at least part information (for example, a part code) to be deleted, frontage information to be deleted (for example, frontage code), and assembly station information related to a part shelf to be deleted. This is done by inputting a delete command.

  Then, in the flowchart of FIG. 12, it is not command reception via communication (step 1201 NO) → terminal operation (step 1208 YES) → component allocation table registration request (step 1202 NO) → component allocation table deletion request (step 1203 YES) ), And thereafter, the update processing (step 1206) of the component allocation table (TB21) stored in the storage means (M2) is executed, and the contents (see FIG. 9) of the component allocation table (TB21) are specified. For the frontage, the registered parts are deleted.

  Next, a registration operation for newly registering another part in the deleted frontage is performed. In the case of the registration operation, it includes at least part information to be registered (for example, part code), frontage information to be registered (for example, frontage code, etc.), and assembly station information related to the part shelf to be registered. This is done by inputting a parts registration command.

  Then, in the flowchart of FIG. 12, it is not command reception via communication (step 1201 NO) → terminal operation is present (step 1208 YES) → part allocation table registration request (step 1202 YES) → Thereafter, the component information included in the command A process (step 1204) for collating (part code etc.) with registered part information (part code etc.) of the part master (MST) is executed.

  The component master (MST) is stored in the storage means (M1), and its contents are shown in FIG. As shown in the figure, in the parts master (MST), for each of the part codes (parts 0001, parts 0002, parts 0003,...) Corresponding to the registered parts, the manufacturer, model, placement location, Parts-related information such as the number of boxes accommodated is stored in association with each other. In the above-described processing (step 1204), for example, the part code requested to be registered is collated with those registered part codes.

  If it is determined that the part code requested for registration does not match any of the registered part codes (NO in step 1205), the part requested for registration is recognized as an unapproved part, and the part allocation table is updated. Is not performed, and the process ends immediately. On the other hand, if the registered component code matches one of the registered component codes (step 1205 YES), the registered component is recognized as an authenticated component and stored in the storage means (M2). The component allocation table (TB21) update process (step 1206) is executed. Then, in the contents of the component allocation table (TB21) (see FIG. 9), the specified allocated component is written for the specified empty frontage.

  On the other hand, every time the component allocation table is updated (including deletion and registration) (step 1206), the updated component allocation table is downloaded to the component shelf management device 3 of the corresponding assembly station (step 1207). Then, although not shown, on the part shelf management device 3 side, it is determined that there is a download, and the storage means (in the component shelf management device 3 (TB21)) is stored based on the contents of the downloaded new component allocation table (TB21). The contents of the component allocation table (TB22) stored in M7) are updated (step 1707).

  Next, the update process of the component allocation table (TB21) by the operation of the component shelf management apparatus side 3 which is the main part of the present invention will be described. Even in the update process of the component allocation table (TB21) by the operation of the component shelf management device side 3, when changing a registered component to another component for a frontage where some component is registered, first, The registered part must be deleted, and then the part code corresponding to the desired part must be registered in the deleted empty frontage.

  When the setting operation to the deletion mode is performed on the touch screen of the programmable terminal (PT) provided in the parts shelf management device 3, as described with reference to FIG. Step 1407) is executed. Details of the delete mode processing are shown in FIG.

  In the same figure, when the process is started, as shown in FIG. 18, on the screen 32a of the programmable terminal (PT) 32, in addition to the chart 32b corresponding to the contents of the parts allocation table (TB22), registration is performed. A button PB1, a delete button PB2, a cancel button PB3, a work end button PB4, a MAIN button PB5, a next screen instruction button PB6, and a previous screen instruction button PB7 are displayed (step 1701). (Step 1702).

  In this state, in the chart 32b corresponding to the contents of the part allocation table (TB22), when a horizontal line corresponding to the frontage or part to be deleted is selected by a touch operation and the delete button PB2 is touched, it is deleted. Is selected (step 1702 YES), the selected part information (part code, etc.) and frontage information (frontage code, etc.) are acquired (step 1703), and the part information and frontage information are obtained. The part allocation table deletion request command generation process (step 1704) is executed, and then the generated part allocation table deletion command is transmitted (notified) to the production process management device 4 (step 1705).

  After that, it waits for the updated new component allocation table (TB21) to be downloaded from the production process management device 4 side (step 1706), and the new component allocation table (TB21) is downloaded. Waiting (YES in step 1706), the contents of the parts allocation table (TB22) stored in the storage means (M7) of the parts shelf management device 3 are updated with the contents of the new parts allocation table (TB21) (steps). 1707), and the process ends.

  On the other hand, referring back to FIG. 12, the production process management apparatus 4 that has received the part assignment table deletion request instruction has received a command via communication (YES in step 1201) → not a part assignment table registration request (NO in step 1202) → part assignment If it is a table deletion request (YES in step 1203), then the update processing (step 1206) of the component allocation table (TB21) stored in the storage means (M2) is executed, and the contents of the component allocation table (TB21) (FIG. 9)), the registered parts are deleted with respect to the frontage specified by the delete command received via communication. Thereafter, the updated parts allocation table is downloaded to the parts shelf management apparatus of the assembly station that is the source of the deletion request (step 1207). As described above, the following returns to FIG. The content of the component allocation table (TB22) stored in the storage means (M7) of the component shelf management device 3 is updated with the content of (TB21) (step 1707), and the processing is terminated.

  Next, an operation for registering a part code corresponding to a desired part in the deleted empty front door will be described. When the setting operation to the registration mode is performed on the touch screen of the programmable terminal (PT) provided in the parts shelf management device 3, as described above with reference to FIG. Step 1405) is executed. Details of the registration mode processing are shown in FIG.

  In the same figure, when the process is started, the supply port opening indicator 22 of the empty opening is blinked (step 1601), and the supply detector 23 of the supply opening of any of the openings is on standby. (Step 1602 NO). Here, the recognition of the vacant frontage is performed by searching for a vacant frontage (a frontage for which no part code is registered) in the frontage part allocation table (TB22) stored in the storage means (M7).

  Then, as shown in FIG. 7 or FIG. 8, the frontage indicators (for example, the display lamps 22a and 22b) attached to the parts supply side openings of the frontage 21 of the parts shelf blink, so that the operator It can be understood at a glance whether the frontage is an empty frontage that has not been assigned a part.

  In particular, when the frontage indicator 22 blinks, if any of the frontage is physically empty, whether it is in a state of waiting for replenishment when a part happens to be used, or the part assignment It is possible to recognize without error whether or not it is due to a state in which no is performed.

  In this state, as shown in FIG. 19, the operator inserts (supplements) the parts required for the registration together with the parts box 5 into the mouth where the frontage indicator 22 is blinking. Then, in the example of FIG. 19, the multi-optical axis photoelectric sensor 23b, which is the frontage detector 23, is activated, and in the flowchart of FIG. 16, it is determined that the detector is activated (YES in step 1602). Detection frontage information (frontage code etc.) corresponding to the activated detector is automatically generated. As will be apparent to those skilled in the art, the automatic generation processing of the detection frontage information is facilitated by, for example, preparing in advance a table that associates the order of scanning the frontage detector 23 with the frontage information. Can be realized.

  Subsequently, regarding the frontage information automatically generated in this way, it is determined whether or not it is frontage information corresponding to an empty frontage. If it is determined that the frontage information is not an empty frontage (step 1604 NO), predetermined error processing is performed. Is executed, for example, a warning light (see FIGS. 7 and 8) attached to the upper part of the parts shelf 2 is activated, and a warning is issued to the worker.

  On the other hand, if it is determined that the automatically generated detection frontage information corresponds to an empty frontage (step 1604 YES), then processing for reading the part information (part code etc.) from the barcode reader 33 (step 1605). ) Is executed. Therefore, after inserting the component box 5 into the empty frontage of the component shelf 2 as shown in FIG. 19, it is pasted on the side surface of the component box 5 by the barcode reader 33 as shown in FIG. When a reading operation is performed on the label 51, the component information (for example, the component code, the manufacturer name, the model, the place of placement, the number of boxes accommodated, etc.) displayed on the label 51 is optically read by the barcode reader 33 ( Step 1605).

  Subsequently, when the registration button PB1 is touched, a component allocation table registration request command is generated from the detection frontage information automatically generated in step 1603 and the component information read from the barcode reader in step 1605 (step 1606). The component allocation table registration command generated in this way is transmitted (notified) to the production process management device 4 (step 1607).

  Then, returning to FIG. 12, the command is received via communication (step 1201 YES) → the component allocation table registration command (step 1202 YES), and then the component information (component code etc.) included in the command is transferred to the component master. A process (step 1204) for collating with registered part information (part code, etc.) of (MST) is executed.

  As described above, the parts master (MST) is stored in the storage means (M1), and the contents are shown in FIG. As shown in the figure, in the parts master (MST), for each of the part codes (parts 0001, parts 0002, parts 0003,...) Corresponding to the registered parts, the manufacturer, model, placement location, Parts-related information such as the number of boxes accommodated is stored in association with each other. In the above-described processing (step 1204), for example, the part code requested to be registered is collated with those registered part codes.

  If it is determined that the part code requested for registration does not match any of the registered part codes (NO in step 1205), the part requested for registration is recognized as an unapproved part, and the part allocation table is updated. Is not performed, and the process ends immediately. On the other hand, if the registered component code matches one of the registered component codes (step 1205 YES), the registered component is recognized as an authenticated component and stored in the storage means (M2). The component allocation table (TB21) update process (step 1206) is executed. Then, in the contents of the component allocation table (TB21) (see FIG. 9), the specified allocated component is written for the specified empty frontage.

  When the component allocation table is updated (step 1206), the updated component allocation table is downloaded to the component shelf management apparatus 3 of the assembly station that is the registration request source (step 1207). Then, returning to FIG. 16, the parts shelf management device 3 determines that there is a download (step 1608 YES), and manages the parts shelf according to the contents of the downloaded new parts allocation table (TB21). The contents of the component allocation table (TB22) stored in the storage means (M7) of the apparatus 3 are updated (step 1609).

  Thus, according to the assembly support system described above, in the parts shelf management device 3 of each assembly station, the operation mode is set to the registration mode, and the frontage detector 23 and the barcode reader 33 are set in the set state. If operated, corresponding detection frontage information is automatically generated based on the detection signal from the frontage detector 23 provided in each frontage 21 of the component shelf 2, and the component information to be registered by the reading operation of the barcode reader 33. Is generated, and a table update request including the automatically generated detection frontage information and the registration target part information generated via the barcode reader is notified to the production process management device 4.

  Then, on the production process management device 4 side, the contents of the frontage component allocation table are updated based on the detected frontage information and the part information included in the table update request notified from the parts shelf management device 3.

  Therefore, according to the present invention, in the parts shelf management device 3 of each assembly station, the operation mode is set to the registration mode, and in the setting state, the frontage detector (for example, the lever switch 23a, the multi-optical axis photoelectric sensor 23b). Etc.) and the barcode reader 33 constituting the component information reader can be operated to remotely update the contents of the part allocation table (TB21) by frontage on the production process management device 4 side, and the assembly work at each assembly station On the part of the worker, the contents of the frontage part allocation table (TB21) on the side of the production management apparatus 4 corresponding to the parts shelf 2 in each assembly station are usually used for an assembly operator who is called frontage code or part code. It can be easily changed without knowing complicated information that is difficult to contact.

  In addition, the parts shelf management device 3 of each assembly station assembles each production model based on the production plan information (INFO 22) for a predetermined number of production units (for example, 100 units) downloaded in advance from the production process management device 4. Since the display operation of the frontage indicators 22 corresponding to the parts required for the work is controlled, even if a situation occurs in which downloading is temporarily disabled due to a network (NET2) abnormality or the like. On the other hand, there is an advantage that the assembly work in the production line does not stop immediately. On the other hand, in the registration mode, when the updated part allocation table (TB21) is downloaded from the production process management device 4 side, Parts-based production plan information for a predetermined number of production units (for example, 100 units) in the management device 3 is allocated to the updated part-by-part parts allocation. By referring to the contents of the table (TB22), it is automatically reconverted to the frontage-based production plan information (INFO31). Therefore, even for the already downloaded production plan, a new frontage part allocation table (TB22) Will automatically play back the one corresponding to.

  In addition, the production process management device 4 includes a component master storage unit (M1) that stores a component master (MST) in which component information relating to all components that can be used at each assembly station on the production line is registered. And the registration target component information included in the table update request notified from the component shelf management device 3 is collated with the component master (MST) stored in the component master storage means (M1). While the contents of the frontage part allocation table (TB21) are updated, the contents of the frontage part allocation table (TB21) are not updated when there is a mismatch. While permitting the update of the part allocation table by frontage, it is possible to avoid the risk that unapproved parts are used without permission and assembly work is performed.

  Further, the parts shelf management device 3 searches for the frontage where no part is assigned based on the contents of the frontage-specific part allocation table (TB22), and blinks the frontage display 22 corresponding to the searched frontage. In the parts shelf 2, even if any of the frontage 21 is empty, the reason is that the part is not assigned, or the part is used by chance. It is possible for the worker to understand at a glance whether the state is waiting for replenishment, and the worker can immediately find a frontage where new parts can be assigned.

  In addition, when the parts shelf management device 3 is set to the deletion mode, the part information that becomes a deletion candidate is guided and displayed based on the empty frontage information in the frontage-specific part allocation table (TB22). An update request including the selected part information and the frontage information is notified to the production process management device simply by performing an operation of selecting information, and the desired part information is thereby sent to the production process management device side It can be deleted from the allocation table.

  In the above assembly support system, the component information reader is an optical code reader, magnetic code reader, or RFID tag reader capable of reading a one-dimensional or two-dimensional optical code displayed on the component storage box 5 or the like. May be. According to such a configuration, when the parts are stored together with the parts box 5 in each frontage 21 of the parts shelf 2, the side of the parts box 5 or the like or the separately prepared parts information list display sheet is displayed in one dimension. If the component information is attached using a two-dimensional optical code, magnetic code, RFID tag, etc., it is only necessary to perform a reading operation using a component information reader, and it is usually in contact with an assembly operator such as a component code. Parts information can be easily input without knowing difficult and complicated information.

  In the assembly support system described above, the parts shelf management device 3 includes a programmable controller that functions as a client body and a programmable terminal that functions as a human machine interface, and the production that constitutes the parts shelf management device. The functions of the plan storage means, the parts assignment table storage means, the operation mode control means, and the registration mode control means are realized by the user program of the programmable controller and constitute the parts shelf management device. Since the function of the mode setting means is realized by the programmable terminal, the present invention can be easily realized without using a special dedicated control device.

  According to the present invention, on the side of the assembly operator at each assembly station, the contents of the part allocation table by frontage corresponding to the parts shelf at each assembly station are referred to as frontage codes and part codes. It is possible to provide an assembly support system applied to a heterogeneous simultaneous production line that can be easily changed without knowing complicated information that is usually difficult for an assembly operator to contact.

It is a layout figure which shows an example of a heterogeneous simultaneous production line. 1 is an overall configuration diagram of an assembly support system according to the present invention. It is a block diagram of a high-order apparatus. It is explanatory drawing which shows the content of the model use parts table (TB1) for every assembly station. It is explanatory drawing which shows the content of the production plan information (INFO21) based on the components used for every assembly station. It is explanatory drawing which shows the content of the components master (MST). It is explanatory drawing (the 1) which shows an example of a components shelf. It is explanatory drawing (the 2) which shows an example of a components shelf. It is explanatory drawing which shows the content of the components allocation table (TB22) in the components shelf for every assembly station. It is explanatory drawing of the frontage information corresponding to the used components for each production apparatus in each assembly station. It is a flowchart which shows the basic process of a production process management apparatus. It is a flowchart which shows the table update process by the side of a production process management apparatus. It is a general flowchart which shows the whole process of a components shelf management apparatus. It is a flowchart which shows the mode setting process of a parts shelf management apparatus. It is a flowchart which shows the detail of an operation mode process. It is a detailed flowchart of a registration mode process. It is a detailed flowchart of a deletion mode process. It is explanatory drawing which shows the example of a display of a programmable terminal. It is explanatory drawing which shows the operating state of a frontage detector at the time of using a multi-optical axis photoelectric sensor as a frontage detector. It is explanatory drawing of the components information reading operation by a barcode reader.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Assembly line 2 Parts shelf 3 Parts shelf management apparatus 4 Production process management apparatus 5 Parts box 10 Assembly line 10a Compartment area 11 Assembling product 12 Assembly worker 13 Multiple carriage 21 Frontage 22 Frontage indicator 22a Display lamp 22b Display lamp 23 Frontage detector 23a Lever switch 23b Multi-optical axis photoelectric sensor 24 Output slave unit 25 Input slave unit 31 Programmable controller (PLC)
32 Programmable Terminal (PT)
32a screen 32b component assignment table display 33 bar code reader 34 warning light 100 upper device PB1 registration button PB2 delete button PB3 cancel button PB4 work end button PB5 MAIN button PB6 next screen instruction button PB7 previous screen instruction button INFO11 production of upper device storage Plan information (model based)
INFO12 Production plan information stored in production process management equipment (model based)
INFO21 Production plan information stored on production process management device (parts based)
INFO22 Production plan information for parts shelf management device (parts base)
INFO31 Frontage information used MST Parts master TB1 Model-specific used parts table TB21 Frontage part allocation table stored by production process management device TB22 Frontage part allocation table stored by part shelf management device NET1 Network linking host device and production process management device NET2 Network connecting production process management equipment and parts shelf management equipment

Claims (6)

Products of different models can be obtained by simultaneously flowing products in the course of assembly of different models to an assembly line in which a plurality of assembly stations are arranged in series, and performing assembly work for each model at each of the plurality of assembly stations. An assembly support system applied to different models simultaneous production lines that can be produced simultaneously on the same assembly line,
A production process management apparatus that is installed in a remote location such as an office separated from the assembly line site and collectively manages the assembly processes in all assembly stations or a plurality of pre-assigned assembly stations included in the assembly line; ,
Each of the plurality of front openings is installed at each site of a plurality of assembly stations included in the assembly line and accommodates components necessary for assembly. A parts shelf provided with a container,
A parts shelf management device installed at each site of a plurality of assembly stations included in the assembly line and connected to the production process management device via a communication network,
In the production process management device,
Higher-order receiving means for receiving model-based production plan information including model information indicating each model and production order information indicating the production order of the model from a predetermined higher-level device for a predetermined number of production units;
For each of a plurality of assembly stations managed by itself, model-specific use in which model information indicating each model and part information indicating parts used in the assembly process of that model in association with each other are registered in association with each other A used parts table storage means for storing a parts table;
For each of a plurality of assembly stations managed by the self, the frontage information indicating each frontage of the parts shelf included in the assembly station and the part information indicating the parts assigned to the frontage are registered in association with each other. Component allocation table storage means for storing a component allocation table;
By referring to the model-specific used parts table stored in the used parts table storage means, the model-based production plan information received from the host device by the receiving means is converted into the parts-based production plan information for each assembly station. Model / part / base conversion means to convert
An update operation means for updating the registered contents of the frontage part assignment table stored in the parts assignment table storage means by an operation on the process management server side;
A first component allocation table that updates the contents of the part allocation table stored in the component allocation table storage unit based on the input window information and the component information input by the registration operation or the deletion operation of the update operation unit Update means;
Second component assignment for updating the contents of the part assignment table stored in the part assignment table stored in the parts assignment table storage means based on the detection window information and the parts information included in the table update request notified from the parts shelf management device Table updating means;
Production plan download means for downloading part-based production plan information for each assembly station obtained from the model / part / base conversion means to the parts shelf management device of each assembly station;
Component allocation table download means for downloading the frontage-specific component allocation table updated by the first and second component allocation table update means to the component shelf management device of the corresponding assembly station; and
In the parts shelf management device of each assembly station,
Production plan storage means for storing part-based production plan information downloaded from the production process management device via production plan download means;
Component allocation table storage means for storing a front-by-side component allocation table downloaded from the production process management device via a component allocation table download means;
A component information reader capable of reading the recorded component information using a machine readable code;
Mode setting means capable of setting the operation mode to at least the operation mode and the registration mode;
Control means for operation mode;
And a control means for a registration mode,
The control means for the operation mode includes
Based on the part-based production plan information stored in the production plan storage means in the parts shelf management apparatus by referring to the frontage part allocation table stored in the parts allocation table storage means in the parts shelf management apparatus Use frontage information generating means for generating use frontage information indicating the frontage corresponding to the used parts for each assembly operation;
Based on the used frontage information generated by the used frontage information generating means and the detection signal from each frontage frontage detector of the parts shelf, the display operation of the frontage display corresponding to the used frontage in each assembly operation is performed. A frontage display control means for controlling,
The control means for the registration mode includes
Detection frontage information generating means for generating corresponding detection frontage information based on a detection signal from a frontage detector provided at each frontage of the parts shelf,
Component information generating means for generating component information to be registered by a reading operation of the component information reader;
Notification means for notifying the process management apparatus of a table update request including the detection front edge information generated by the detection front edge information generation means and the registration target part information generated by the part information generation means is included. And
Accordingly, in the parts shelf management apparatus of each assembly station, the operation mode is set to the registration mode, and the frontage detector and the part information reader are operated in the set state, thereby the production process management apparatus. The contents of the frontage part allocation table stored in the part allocation table storage means on the side can be remotely updated,
An assembly support system for simultaneous production lines of different models. In the production process management device,
The production plan download means includes
It is structured to download part-based production plan information for each assembly station obtained from the model / part / base conversion means to the parts shelf management device of each assembly station in a batch for a predetermined number of production units. And in the parts shelf management device of each assembly station,
The production plan storage means in the parts shelf management device has a storage capacity capable of collectively storing the parts-based production plan information downloaded from the production process management device via the production plan download means for a predetermined number of production units. And
In the control means for the normal mode,
The frontage display control means includes:
The frontage information corresponding to the frontage used for each one that is sequentially extracted from the frontage-based production plan information for the predetermined number of production units stored in the production plan storage means in the parts shelf management device, and each of the parts shelf Based on the detection signal from the frontage frontage detector, it is designed to control the display operation of each frontage frontage indicator corresponding to the parts required for assembly work of each production model, and the registration mode Control means for
The frontage information generating means
By referring to the contents of the updated part allocation table that is downloaded and stored in the component allocation table storage means in the parts shelf management apparatus, the contents are stored in the production plan storage means in the parts shelf management apparatus. The system is designed to reconvert parts-based production plan information for a given number of production units into frontage-based production plan information.
The assembly support system in the heterogeneous simultaneous production line according to claim 1. In the production process management device,
A component master storage unit that stores a component master formed by registering component information about all components that can be used at each assembly station on the production line, and the second component allocation table update unit includes: The registration target component information included in the table update request notified from the component shelf management device is collated with the component master stored in the component master storage means, and when the collation matches, the contents of the frontage component allocation table are In contrast, when the verification does not match, it is structured not to update the contents of the frontage component allocation table.
The assembly support system in a heterogeneous simultaneous production line according to claim 2. In the parts shelf management apparatus,
Control means for the registration mode include
Based on the contents of the part allocation table storage table stored in the part allocation table storage means in the parts shelf management device, the frontage where no part is assigned is searched, and the frontage display corresponding to the searched frontage Includes a registerable frontage guide means that operates in a predetermined display mode,
The assembly support system in the heterogeneous simultaneous production line according to any one of claims 1 to 3. In the parts shelf management device of each assembly station,
In addition to the operation mode and the registration mode, the mode setting means can be set to the deletion mode, and a control means for the deletion mode is provided,
The control means for the deletion mode is:
Deletion candidate guidance display means for guiding and displaying part information as a deletion candidate based on empty frontage information in the frontage part allocation table stored in the part allocation table storage means in the parts shelf management device;
A deletion target selection unit for selecting desired component information from the component information that is a deletion candidate guided and displayed by the deletion candidate guidance display unit;
Notification means for notifying the production process management device of an update request including part information and frontage information selected as deletion targets by the deletion target selection means,
The assembly support system in the heterogeneous simultaneous production line according to any one of claims 1 to 4. The parts shelf management device
It consists of a programmable controller that functions as a client body and a programmable terminal that functions as a human machine interface.
Each function of the production plan storage means, the parts allocation table storage means, the operation mode control means, and the registration mode control means constituting the parts shelf management apparatus is realized by the user program of the programmable controller. And the function of the operation mode setting means constituting the parts shelf management device is realized by the programmable terminal,
An assembly support system in a heterogeneous simultaneous production line according to any one of claims 1 to 5.

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