JP2013069234A - Supply plan preparation system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a supply plan preparation system for suppressing surplus stock of an assembly line, simplifying a line side, and improving productivity and workability without lowering supply efficiency of components.SOLUTION: A supply plan preparation system 1 supplies a plurality of components continuously to a line side 5a by a lot unit. The supply plan preparation system 1 includes: line stock zones 070-183 provided on the line side 5a for assembling the components; supply means 7 for loading and supplying the components; conveyance means 71 for conveying the supply means 7; a product assembly information storage part 11 storing component configuration information and production plan information 112; a supply means information storage part 12 storing supply means identification information 121 and loading allowable number information 122; and a supply plan preparation part 14 for developing the quantity and the supply time of the components to be loaded on the supply means 7.

Description

  The present invention relates to a supply plan creation system for creating a plan for supplying parts used in each process of an assembly line to a line inventory area provided along the assembly line.

  Conventionally, as a system developed to efficiently carry parts from the parts management base (parts management center) to the assembly line in the factory, for example, for each part stocked in each process of the assembly line, the part is 2. Description of the Related Art A process management apparatus is known that calculates a scheduled time for consumption of all and manages processes so that parts are carried into an assembly line at that time (see, for example, Patent Document 1).

  This process management device calculates the production rate change registration unit that collects the planned production volume of products scheduled to be produced on the assembly line from the input device during the specified operation time, and the speed at which parts are consumed based on the planned production volume. A delivery time calculation unit that divides the operation time into a plurality of times based on the speed and calculates a plurality of delivery times, and an instruction to carry parts from the parts management base to a process on the assembly line at a plurality of delivery times. A carry-in instruction unit that outputs to the output device, and a carry-in amount calculation unit that calculates the carry-in amount of components carried in at a plurality of carry-in times when all the components are consumed in the process are configured.

  In this process management device, by loading the necessary parts on the carriage at the appropriate timing for each part according to the scheduled time when all parts in stock in each process of the assembly line are consumed, The amount of parts stocked in each process of the assembly line is reduced.

Japanese Patent No. 4229892 (paragraph [0014], FIG. 1 and FIG. 2)

  However, in the conventional parts supply system to the assembly line, priority was given to improving transport efficiency in transportation from the supplier to the parts management base and parts supply from the parts management base to the assembly line. Depending on characteristics such as weight and weight, the packaged form was consolidated (maximum number of individual charges) and supplied to the line side with the maximum number of individual charges managed for each part.

For this reason, especially in the case of an assembly line that produces products with many derivatives depending on the type and color of the production model, various excess inventory parts are often flooded temporarily on the line side, compressing the line side space. There was a situation.
This line-side surplus inventory component can cause misplacement of parts and cause workers to assemble wrong derivative parts, making it difficult to assemble parts to deteriorate workability, or trucks with surplus parts on them. Due to the mixture, various problems such as forcing frequent rearrangement work of carts are caused, and there is a problem that productivity and workability are deteriorated.

  Accordingly, the present invention has been invented to solve the above-mentioned problems, and does not reduce the supply efficiency of parts, suppresses excess inventory on the assembly line, simplifies the line side, and improves productivity and workability. It is an object to provide a supply plan creation system.

  In order to solve the above problems, a supply plan creation system according to the present invention supplies a part to a line side in an assembly line for assembling a plurality of parts and continuously producing different types of products in units of predetermined lots. A supply plan creation system, which is provided on the line side and accommodates parts to be assembled in each process of the assembly line in predetermined sections, and loads the parts to load the parts. Supply means accommodated in the line stock area, transport means for transporting the supply means to the line stock area, parts configuration information which is a list of parts assembled in the product, and each product flowing on the assembly line A product set for storing lot size, production order of each product, and production plan information in which the number of lots is planned together with production time An information storage unit, a supply unit identification information for grasping a classification of loaded components, a loading unit number information for grasping a loading allowable number of loaded components, and a component loaded on the supplying unit And a supply plan creation unit that formulates the quantity and supply time of the parts, and the supply plan creation unit loads the supply means based on the part configuration information and the production plan information. The number of used parts to be stored in the predetermined line stock area is specified, the lot usage number calculating means for obtaining the number of used parts used for each lot, and the plurality of types of used parts are used in succession. Of the continuous lot number calculating means for obtaining the number of lots to be obtained, and among the continuous lot numbers of the plurality of types of used parts obtained by the continuous lot number calculating means, one line loaded on the supply means Among the combinations of parts to be supplied to the warehouse area, the minimum continuous lot number calculating means for obtaining the minimum number of continuous lots and the continuous lot number equal to or less than the minimum lot number are adopted to cover the selected continuous lot number Supply part number calculating means for obtaining the number of used parts of a plurality of types, and having the used quantity of the plurality of kinds of used parts obtained by the supply part number calculating means loaded on the supply means to the line inventory area It is characterized by preparing a supply plan for supply.

According to this configuration, the supply plan creation system uses the lot usage number calculation unit of the supply plan creation unit based on the part configuration information and the production plan information to load the supply unit and supply it to a predetermined line inventory area. Since parts are identified and the number of used parts to be used for each lot is obtained, parts with the number of parts in lot units that match the production plan can be supplied to the line side to simplify the line side. .
In addition, the supply plan creation unit loads the number of used parts of the plurality of types of parts used to cover the number of consecutive lots less than or equal to the minimum lot number calculated by the minimum continuous lot number calculation unit by the supply part number calculation unit. Therefore, it is possible to suppress excess inventory parts that are not used up on the line side, improve visibility, and prevent mistakes in the parts of the operator. In addition, for example, even if the packaging of parts is consolidated, delivery from the supplier to the parts management base in units of lots reduces the man-hours for converting requirements (refilling) to the assembly line and simplifying it. be able to.
Furthermore, the supply plan creation unit adopts the maximum lot number among the continuous lot numbers equal to or less than the minimum lot number by the supply part number calculation means, while supplying without reducing the supply efficiency of the parts, It is possible to efficiently supply parts while suppressing excessive stock parts from accumulating in the assembly line.
As a result, a plurality of types of parts loaded on the supply means can be used up at the same timing in lot units, and the supply means can be quickly recovered, thereby improving the rotation efficiency of the use cycle of the supply means. At the same time, extra parts can be eliminated on the line side. Further, even when a large number of parts are purchased, it is possible to supply the necessary parts on the line side in a necessary amount in a timely manner.
In this way, the supply plan creation system according to the present invention eliminates erroneous assembly of parts, reduces the supply efficiency of parts, suppresses excess inventory on the assembly line, and simplifies the line side for production. And workability can be improved.

  Further, the assembly line is divided into a plurality of zones, and the product assembly information storage unit further stores production progress information obtained by grasping the production amount of the product that actually flows through the assembly line together with the production time, The supply plan creation unit includes a supply instruction time calculation unit that calculates a supply instruction time of the supply unit, a supply allowable time calculation unit that calculates a supply allowable time by adding a delay possible time with respect to the supply instruction time, and the same zone Arranged in order from the supply instruction time in the supply means to be supplied to the line stock area within, the supply means of the latest supply instruction time does not exceed the supply allowable time for the supply means of the earliest supply allowable time, and A supply means group selection section for selecting a combination of the supply means so that the overall connection length is within an allowable connection length, Means are preferably transported to the line inventory area by connecting a plurality of supply means which is selected by said supplying means group selection unit.

  According to such a configuration, the transportation means efficiently supplies the parts to the line inventory area in a timely manner by connecting the plurality of supply means selected by the supply means group selection unit to the line inventory area. Excess inventory parts can be eliminated.

  In addition, the transport means connects a plurality of supply means selected by the supply means group selection unit in series from the head to the tail, and from the part near the line stock area to be supplied as viewed from the part management base side. It is preferable to connect the closer supply means to the rear and connect the far supply means to the head so as to supply in the order of farther.

  According to such a configuration, the conveying means connects the plurality of supply means selected by the supply means group selection unit in series from the head to the tail, and is close to the line inventory area to be supplied as viewed from a predetermined parts management base. By connecting the closer supply means to the tail and connecting the distant supply means at the head so as to supply in order from the far side to the far side, the parts can be efficiently supplied to the line side, and empty on the line side. The supply means in the state can be efficiently recovered.

  In addition, the supply plan creation unit may include a supply schedule setting unit that sets the supply instruction time for the supply means having the latest supply instruction time among the plurality of connected supply means as a supply representative time. preferable.

  According to this configuration, the supply plan creation unit includes the supply schedule setting unit that sets the supply instruction time for the supply unit having the latest supply instruction time among the plurality of connected supply units as the supply representative time. The timing to use up the parts can be used up at the same time in accordance with the latest supply instruction time. For this reason, it can suppress that many kinds of parts and many supply means remain in a line stock area.

  The supply plan creation unit creates the supply plan for each plan target range that divides time, day, target lot range, and other predetermined ranges, and has the supply instruction time within the plan target range. A transport preparation start data storage means for storing data for specifying a transport preparation start transport means that has started the transport preparation based on the supply plan, and a transport preparation start data storage means. Reorganization reference time for referring to the transfer preparation start data (actual data) and determining the supply instruction time for the latest transfer preparation start transfer means and adding a grace time to this supply instruction time Setting means, and in addition to the supply plan creation target transport means, before the plan target range to which the supply plan creation target transport means belongs, and Incorporate conveying means having a feed instruction time later than the restructuring reference time, it is preferable to create the supply plan.

  According to such a configuration, since the prepared supply plan includes the conveyance means having the supply instruction time created in the past planning target range, the reorganization of the past planning target range with respect to the unstarted conveyance means is performed. Thus, a supply plan that improves the conveyance efficiency can be created.

  The supply plan creation system according to the present invention eliminates erroneous assembly of parts, reduces the supply efficiency of parts, suppresses excess inventory in the assembly line, simplifies the line side, and improves productivity and workability. Can be improved.

It is a figure which shows an example of the supply plan preparation system which concerns on embodiment of this invention, and is the schematic which shows the components management base installed adjacent to the factory. It is a principal part schematic diagram which shows an example of the use condition of the trolley | bogie in the supply plan preparation system which concerns on embodiment of this invention. It is the schematic which shows the use cycle of the trolley | bogie in the supply plan preparation system which concerns on embodiment of this invention. It is the schematic which shows the assembly line and line side in a factory in the supply plan preparation system which concerns on embodiment of this invention. It is a figure which shows an example of the supply plan preparation system which concerns on embodiment of this invention, and is a principal part schematic plan view which shows the assembly line and line stock area in a factory. It is a figure which shows supply and refilling of the components in the supply plan preparation system which concerns on embodiment of this invention, and shows the transition of the supply timing of the components with respect to an assembly line, the trolley | bogie which loads components, and the inventory of a line side component. It is explanatory drawing. It is a figure which shows the comparative example at the time of supplying parts with the number of individual charges of the supplier, and shows the transition of the supply timing of parts to the assembly line, the truck on which the parts are loaded, and the inventory of parts on the line side It is explanatory drawing. It is a block diagram which shows the system configuration | structure of the supply plan preparation system which concerns on embodiment of this invention. It is explanatory drawing which shows the schedule date of the trolley | bogie connected with the same train in the supply plan preparation system which concerns on embodiment of this invention. It is a table | surface which shows the relationship between the retrain combination of the cart which has not started work in the supply plan creation system which concerns on embodiment of this invention, a lot, and time. It is a flowchart which shows the process of the demand repack in the supply plan preparation system which concerns on embodiment of this invention. It is a flowchart which shows the process of the dynamic train build in the supply plan preparation system which concerns on embodiment of this invention. It is a flowchart which shows the reorganization of the trolley | bogie of the train in the supply plan creation system which concerns on embodiment of this invention.

Hereinafter, a supply plan creation system according to an embodiment of the present invention will be described with reference to the accompanying drawings, taking as an example an assembly line for assembling an automobile (product) from a plurality of parts. The present invention can be applied to any assembly line (production line) that completes a product by assembling supplied components, and is not particularly limited to component supply means, components, and products.
As shown in FIG. 1, a supply plan creation system 1 (see FIG. 8) according to an embodiment of the present invention is configured to produce a large number of various types of parts produced by a supplier 2 and transported to a parts management base 4. 5 is a system for creating a supply plan to be supplied to five assembly lines 6.
Before describing the supply plan creation system 1, the supplier 2, the trailer yard 3, the parts management base 4, the factory 5, the assembly line 6, and the like will be described.

<Supplier configuration>
The suppliers 2 are respective suppliers who produce parts and supply them to the parts management base 4 by ships, airplanes, trucks, trailers, other freight vehicles (hereinafter referred to as “trailers”). Inspection and sorting are performed based on the ordering information from the factory 5, packing is performed for each number of delivery items based on the lot standard determined in advance, and the quantity of parts based on the number of orders is delivered. For example, a large number of parts manufactured and shipped at a domestic supplier 2 manufacturing factory or a large number of parts produced by an overseas supplier 2 and imported by a ship or the like are shipped via a relay center such as a distribution center. And is conveyed directly to the trailer yard 3 by the trailer 21.
In other words, the parts 2 of the supplier 2 are shipped in such a way that the supplier 2 is transported and delivered individually with the maximum number of lots in a lot unit.

<Configuration of trailer yard>
As shown in FIG. 1, the trailer yard 3 (Trailer yard) is a place where, for example, a trailer 21 loaded with parts to be newly delivered to the parts management base 4 or a trailer 22 that has finished delivering parts is parked. Yes, adjacent to the parts storage area 40 of the parts management base 4. An automatic recognition device 31 that recognizes the entrance and exit of the trailers 21 and 22 is disposed at the entrance and exit of the trailer yard 3.

<Configuration of parts management base>
The parts management base 4 is a warehouse for preparing parts for receiving, storing, and supplying parts from each supplier 2 conveyed by the trailer 21 and for supplying the parts, and is adjacent to the factory 5 continuously. The parts management base 4 includes, for example, a parts storage area 40 arranged on the trailer yard 3 side in the parts management base 4, a large parts storage area 41 adjacent to the parts storage area 40, and parts storage. A small parts storage area 42 that is adjacent to the area 40 and is disposed symmetrically with respect to the large parts storage area 41, and a repack area that is disposed between the small parts storage area 42 and the large parts storage area 41. 43, a train path 4a disposed from the repack area 43 toward the line side 5a of the factory 5, and a train build area 44 disposed adjacent to the large parts storage area 41 and facing the train path 4a. And the RCC 45 arranged at the position on the factory 5 side facing the train passage 4a, and the RCC 45 opposed to the train passage 4a across the train passage 4a. Staging Elijah 46, it is provided. The parts management base 4 may be provided in the factory 5.

  In this manner, the parts are supplied in the parts management base 4 from the supplier 2 through the trailer yard 3 by the trailer 21 in a packed state produced by the supplier 2. Each area of the parts management base 4 determines the necessity of refilling the parts in the packed packaging according to the continuity of production based on the production information from the assembly line 6 of the factory 5 (demand repacking) ) And then refilling the supply package, the necessary amount is delivered to the assembly line 6. For this reason, it is possible to eliminate excess inventory on the side of the assembly line 6.

  The parts storage area 40 is an area in which the parts received by the trailer 21 are unloaded from the trailer 21 by a forklift and the same kind of parts are temporarily stored by type. In addition, the parts conveyed by the trailer 21 are delivered to the container and are identified and managed by bar codes.

  As shown in FIG. 1, the large parts storage area 41 stores the large parts classified into large parts among the parts once stored in the parts storage area 40 at a predetermined parts storage location. When the instruction to leave is received, the area prepares for leaving so that it can be mounted on a predetermined towed truck 72 by a forklift or the like.

  The small parts storage area 42 stores the small parts classified into the small parts among the parts once stored in the parts storage area 40, and stores them in a predetermined parts storage place. Then, it is an area that prepares for delivery so that it can be mounted on a predetermined towed truck 72 with a forklift or the like. The small parts storage area 42 and the like can be automatically conveyed, automatically sorted and automatically delivered by, for example, a barcode system and an automatic delivery device.

  Repack Area 43 (Repack Area) stores necessary parts in the packing form packed by supplier 2 in a supply packing form that is refilled according to the requirements of assembly line 6 when necessary. And Eliya who prepares for supply. The repack area 43 is a place for performing so-called demand repacking which will be described later. The repack area 43 determines the number of supply possible based on the load capacity of the cart 70 and the continuity of the applied parts based on some information of the supply plan, and minimizes the change from the packaging state of the supplier 2 to the minimum. Refill.

  A train build area 44 (Train Build Area) is an area that configures a train by connecting a plurality of towed trucks 72 based on a supply plan, and is a place where a so-called dynamic train build is organized. In other words, the train build area 44 does not cut the line inventory in the same zone of the assembly line 6 to which the plurality of towed trucks 72 loaded with the parts finally sent to the assembly line 6 are left, and the line side inventory remains. As a result of determining the connection of trains with good connection efficiency and delivery efficiency at a slight timing, this is a place where the carts 70 to be connected are connected.

  The RCC 45 is an area for collecting and temporarily storing empty individual containers 8.

  The staging area 46 (Staging Area) waits for a train that is formed by connecting a plurality of towed trucks 72 loaded with parts accommodated in the individual containers 8 until a designated supply instruction time is reached. It is. When the designated supply instruction time is reached, the operator connects the train to the towing cart 71 and supplies the parts to the assembly line 6.

≪Part composition≫
The parts are assembled to the vehicle body in the assembly line 6, and there are three types of so-called common parts, variable parts, and unique parts. The common part is a part that is commonly applied to the same model (vehicle type) in all production model types and colors, and is, for example, a screw or the like. The variable part is a part in which derivative parts having the same function are alternately applied according to the production model type and color, for example, a door knob that differs depending on the vehicle type and color of the vehicle body. The unique part is a dedicated part that is applied only to a specific production model type and color, and is, for example, a part that is mounted only on a high-grade vehicle body. These parts are stored and delivered by the supplier 2 in predetermined containers (lot units) set in advance in the individual containers 8 (see FIG. 2).

≪Composition of bogie≫
As shown in FIG. 1, the carriage 70 (supply means 7) is a wheeled carriage used when supplying the parts at the parts management base 4 to the line side 5 a of the factory 5. As shown in FIG. 2, the cart 70 includes a tow cart 71 that is driven by an operator and moved by a motor, and a plurality of tow carts 72 that are pulled by the tow cart 71 and load components. Configure one train.

As shown in FIG. 1, the tow truck 71 pulls a towed truck 72 loaded with parts stored in the individual container 8 and stored in the parts management base 4 from the parts management base 4 in the factory 5. It is a vehicle with a drive source that is supplied to the line side 5a of the line 6, and is connected to the head of the train.
As shown in FIG. 2, the towed truck 72 constitutes a vehicle other than the leading vehicle of the train connected within a preset full length range by connecting a plurality of towed trucks 72 to the towed truck 71. . The towed truck 72 includes a single truck that loads one type of component and a mixed truck that loads a plurality of types of parts.

<About the connection order of trucks (dynamic train build)>
As described above, the trolley 70 is arranged with the traction trolley 71 (conveying means) at the head, and connects a plurality of towed trolleys 72 (supply means 7) selected by the supply means group selection unit 147 (see FIG. 8). Thus, a train is configured, and the components in the individual container 8 loaded on the towed carriage 72 are conveyed to the line stock areas 070 to 183 (see FIG. 5). The tow truck 71 connects the plurality of towed trucks 72 selected by the supply means group selection unit 147 (see FIG. 8) in series from the head to the rear, and supplies the line stock area 070 as viewed from the parts management base 4. ~ 183 so as to supply in order from the nearer to the farther, the closer towed truck 72 is connected to the tail and the farther towed truck 72 is connected to the head (dynamic train build) ).

In other words, the trolley 70 is configured such that the towed truck 72 is connected in order of delivery from the tail to form a train with the towed truck 71 at the top, and when the truck is delivered, the towed truck 72 is separated in order from the tail of the train. When the train is released and the tow truck 71 returns, the empty tow truck 72 is sequentially collected and added to return the aisle 5b (see FIG. 5) while assembling the train.
The length of the train is determined by calculating the maximum length (maximum number of connected vehicles) from the length of each towed carriage 72, the width of the line side 5a and the aisle 5b, and the size of the curve.

Next, the cycle in which the carriage 70 is moved and used will be described.
As shown in FIGS. 3 and 4, the cart 70 has a towed truck 72 loaded with parts on the line side 5 a of the factory 5 by loading parts on the towed truck 72 </ b> C at the parts management base 4 and forming a train. Supplied with each. When the parts loaded on the towed truck 72A are used for the body of the assembly line 6 in the line stock areas 070 to 183 on the line side 5a, the empty towed truck 72B is obtained. The empty towed truck 72 </ b> B loads the empty individual container 8 and returns to the parts management base 4, and repeats a use cycle in which the parts are loaded and supplied to the line side 5 a of the factory 5.

≪Factory configuration≫
As shown in FIG. 1, the factory 5 has an assembly line 6 for assembling and manufacturing automobiles, and the line side 5a of the assembly line 6 is connected to the train passage 4a. In the factory 5, an assembly line 6 for assembling parts to the vehicle body, a line side 5a adjacent to the side of the assembly line 6, and an aisle 5b inside the line side 5a are arranged.

≪Configuration of assembly line≫
As shown in FIG. 5, the assembly line 6 is a production line in which assembly places for performing each process from the first process for performing a number of processes for assembling parts to the vehicle body to the final process are continuously arranged in a U-shape in a rosary shape. It is. The assembly line 6 is bent in a U shape between an inlet 6a through which the vehicle body is supplied to the assembly line 6, an outlet 6b through which a vehicle as a product with parts assembled is sent out, and the inlet 6a and the outlet 6b. The U-turn part 6c is formed, and the inlet 6a side and the outlet 6b side are arranged close to each other. Inside the U-shaped assembly line 6, the line side 5 a arranged along the assembly line 6, and the line side 5 a are divided according to the supply range in which the parts are supplied for each towed truck 72. A line stock area 070 to 183 and an aisle 5b that is arranged inside the line stock area 070 to 183 arranged in series in a U-shape and to which a carriage 70 (see FIGS. 1 and 2) travels are provided. . The assembly line 6 includes a conveyor for transporting semi-finished vehicle bodies, and each assembly operation is performed in which predetermined parts are assembled every predetermined time set in advance. A tact system is used for transporting.

<Configuration of line side and aisle>
On the line side 5a of the assembly line 6, a towed truck 72 loaded with parts separated from the train is disposed. The line side 5a has, for example, a space for placing three towed carriages 72, and normally two are resident. On the line side 5a, the ratio of the towed truck 72 loaded with components and delivered to the towed truck 72 collected in an empty state is basically 1: 1. Note that the replacement frequency of the towed truck 72 varies depending on the process of the assembly line 6 and the number of parts loaded on the towed truck 72.
The aisle 5 b is a passage through which the carriage 70 and the operator come and go, and is along the assembly line 6.

The line stock areas 070 to 183 are predetermined supply locations for separately storing parts to be assembled in each process of the assembly line 6 and are provided on the line side 5a. The numbers “070 to 183” are the address numbers to be assembled and the addresses of the vehicle bodies to be assembled. In addition, the line stock areas 070 to 183 also serve as delivery locations for supply locations where parts are transported by the carriage 70 (see FIG. 2). For example, the line side 5a of the assembly line 6 is divided into three delivery zones from zones #A to #C in which a plurality of adjacent delivery locations are grouped in arbitrary units.
Zone #A to zone #C are a lump of parts supply locations that can be bundled in the same train, and are set within a range that can be delivered at once through the same passage.

  As shown in FIG. 5, the zone #A includes, for example, a line stock area 070 to 090 at the inlet 6a of the assembly line 6 and a line stock at an opposite position with the aisle 5b sandwiched between the line stock areas 070 to 090. The area is from 167 to 183. The zone #B is, for example, the line stock area 091 to 110 and the line stock area 091 to 110 to the line stock area 148 to 166 at the opposite position across the aisle 5b. Zone #C is, for example, the line inventory areas 111 to 147 before and after the U-turn portion 6 c of the assembly line 6.

  Zone #A includes delivery locations for aisle 5b in line inventory area 070-090 and aisle 5b in line inventory area 167-183, so multiple lots ("N + 2", "N + 3", "N + 6") The train is assembled for the towed truck 72 loaded with the parts used in the above, and the parts are stocked together with the towed truck 72 in order from the front side in a zigzag direction to the left and right while running the aisle 5b in the U-shaped line side 5a. By supplying the areas 070 to 090 and 167 to 183, it is possible to carry them at once.

  As described above, since the assembly line 6 has delivery zones set for each aisle 5b, parts of different production lots can be delivered by being assembled into the same train if the use timing is close. The connection efficiency can be improved.

When parts are supplied to the zone #A by the carriage 70, the towed carriage 72 loaded with the ordered parts is moved from the train while moving along the aisle 5b from the inlet 6a of the assembly line 6 toward the zone #B. The separated tow trucks 72 are stored in the line stock areas 070 to 090 and 167 to 183 of the line side 5a.
The one-train traction carriage 71 that has finished distributing the parts returns to the towing trolley 72 loaded with an empty container while being recovered from the aisle 5b.

  In this way, in the zone #A, in the forward path for supplying the parts, the towed truck is directed from the inlet 6a of the assembly line 6 closer to the parts management base 4 toward the zone #B farther from the parts management base 4. In the return path that proceeds while separating 72 and collects the towed truck 72, the vehicle moves from zone #B farther from the parts management base 4 to the entrance 6a of the assembly line 6 closer to the parts management base 4. Thus, the empty towed truck 72 can be efficiently collected.

≪About loading conditions of parts to be loaded on the carriage≫
The unit of supply by loading parts on a cart is 30 units of lot units.
Only when the same part number and the same part color are used in the production of a plurality of consecutive lots, loading to the towed truck 72 used for supplying from the parts management base 4 to the line side 5a of the factory 5 The principle is to load and supply them together within the allowable range. For this reason, when the sum total of the required number is not the common multiple of the number of individual charges, a fraction is generated, and a refilling operation for refilling the packaged parts from the supplier 2 to a predetermined number is required. Note that the number of parts placed on the towed truck 72 may be plural depending on the size of the parts. That is, in the case of a large part that cannot be mounted on one towed truck 72, it may be supplied continuously in two units in the front and rear.

  The load capacity of the towed truck 72 is n times (common multiple) the number of containers received from the supplier 2 and is based on the number of containers. When part numbers and part colors of parts used at the same place on the assembly line 6 are applied continuously, they are loaded together within the allowable loading range of the towed truck 72 and supplied to the line side 5a. .

  The logic for calculating the number of lots that can be carried out is the same for the single cart and the mixed cart. However, in the case of a mixed carriage, the supply number is adjusted according to the parts with the smallest cover lot range among the parts to be mixed, and the cover lot range of the parts mixedly loaded on the same carriage 70 is made equal. Multiple parts are used up at the same time. However, unique parts that are not applicable are not subject to supply number adjustment while non-applications continue. Note that all the parts loaded on one carriage 70 are supplied to a predetermined one of the line stock areas 070 to 183.

≪Demand repack configuration≫
Next, how to load the parts to be supplied to a predetermined one of the line stock areas 070 to 183 on the towed truck 72 will be described with reference mainly to FIG. The demand repack is a general term for a method of determining a supplyable number and a refilling determination method capable of collecting the supply numbers.
In FIG. 6, 1-16 of “Lot #” in the first row indicate the production order of automobiles, and the number of production units is 30 lots as one lot. Production types AB1, AD5 and AB0 in the first row represent the types of vehicle bodies to be produced. “5555-SNE”, “5555-SDA”, “33333-SNA”, and “12345-SDA” in the 4th to 7th lines represent the part model numbers. The parts having the part numbers “5555-SDA” and “5555-SNE” are variable parts, and any one of the parts is used depending on the production model type and color. “33333-SNA” is a unique part and is used only for a specific production model type and color. The part number “12345-SDA” is a common part that is always used. The eighth line represents the supply timing of the towed truck 72.

  In lots # 1 to # 4, the part numbers “5555-SNE” and “12345-SDA” correspond to 4 lots of 30 each, which is the allowable range of the individual container 8 loaded on one towed truck 72. 120 parts are placed in two individual containers 8 for each part number, loaded on one towed truck 72 (721), and supplied to the line side 5a. Each of the 120 parts of the part numbers “5555-SNE” and “12345-SDA” on the towed truck 72 (721) is 30 parts when the assembly work of lot # 1 is completed. Ninety remaining, 60 remaining at the end of the assembly work of lot # 2, 30 remaining at the end of the assembly work of lot # 3, and towed truck 72 (721) at the end of the assembly work of lot # 4 ) The above parts are used up with the remaining zero at the same time, and the individual container 8 becomes empty.

In this way, at the same time as the assembly work of the parts of lot # 4 is completed, all the parts loaded on the towed carriage 72 (721) are used up to zero on the line side 5a. Since the tow cart 72 (721) and the individual container 8 are also empty, the tow cart 72 (721) and the individual container 8 can be removed from the line side 5a and simplified.
Further, when the assembly work of lot # 4 is completed, the remaining parts are zero, so that when disassembling lot # 5, which will be described later, one of the different types of parts used in lots # 1 to # 4 is used. Since it does not remain, incorrect assembly can be prevented.

  In the embodiment, the case where the parts of lots # 1 to # 4 are loaded on one towed truck 72 (721) and supplied to the line side 5a has been described. When supplying a large part that cannot be loaded on one towed truck 72, the parts may be loaded on a plurality of towed trucks 72 and supplied once or multiple times. For example, the large parts of the lots # 1 to # 4 may be loaded in four towed trucks 72 (721) and supplied to the line side 5a.

  In lot # 5, part numbers “5555-SDA” and “12345-SDA” each carry 30 parts in one lot, so “parts mixed on the same carriage have the same number of lots to cover. There is. ”In accordance with the part number“ 5555-SDA ”having a narrow cover range, the supply number of 30 lots is placed in the individual container 8 and loaded on one towed carriage 72.

  For the 30 parts of the part numbers “5555-SDA” and “12345-SDA” on the towed truck 72 (722), when the part assembling work of lot # 4 is completed, the remaining parts are also zero at the same time. As a result, the individual container 8 becomes empty. The towed truck 72 (722) is loaded with only the number of parts supplied in the same cover range as the parts of “15555-SDA” even in the parts of “12345-SDA” used in all lots. Do not load. Therefore, erroneous assembly of parts can be prevented.

  In lots # 6 to # 8, two lots of the same production type and the same part number continue for three lots. Therefore, a total of 90 two parts for three lots of 30 pieces are put in the individual container 8 respectively. It is loaded on the towed truck 72.

In lot # 9, 30 lots are supplied for each lot according to the part number “33333-SNA” with a narrow cover range in the part numbers “55555-SNE”, “33333-SNA”, and “12345-SDA”. The container 8 is loaded and loaded on one towed truck 72.
Since the lots # 10 to # 12 are the same as the lots # 6 to # 8, description thereof is omitted.

Lot # 13 is a small lot in which 15 parts with the part number “55555-SNE” and 15 parts with the part number “5555-SDA” are mixed, and the number of units produced in one lot is an option of 15 units. is there. In this case, 15 parts with the part number “5555-SNE” and 15 parts with the part number “5555-SDA” are mixedly mounted according to the condition that “the small lot should be carried out alone and not mixed with other lots”. After the refilling operation to be performed, one lot is loaded on one towed truck 72 and carried out.
Here, the small lot refers to a lot in which the same model type is produced in principle with 30 lots, but a plurality of model types that are rarely produced only in small quantities are collected into 30 lots.

  In lots # 14 to # 16, each of the part numbers “5555-SDA” and “12345-SDA” continues for 3 lots. Put it on one towed truck 72.

  Thus, according to the present invention, when assembling parts on the assembly line 6, the parts are always loaded on the towed carriage 72 and supplied to the line side 5a in units that are used up, whereby each towed truck 72 (721 to 727) is supplied. ) Can be supplied so that the individual containers 8 are empty at the same time. For this reason, simplification can be achieved by suppressing the number of towed carriages 72 loaded with parts on the line side 5a from being mixed at the same time.

≪Comparison example of shipping parts by the number of individual suppliers of parts≫
Next, referring to FIG. 7 showing a comparative example, a comparative example in which parts are shipped on the basis of the number of individual charges (120 pieces) of the supplier 2 will be described, and the advantages of the present invention will be described. To do. In the comparative example, since the parts in the individual container 8 are not refilled, the number of individual parts is always 120 units.

  In lots # 1 to # 4, as in the embodiment of FIG. 6, the part numbers “5555-SNE” and “12345-SDA” are allowable ranges of the individual containers 8 loaded on one towed truck 72. 120 parts for 4 lots of 30 are placed in two individual containers 8 for each part number, loaded on one towed truck 72 and carried out. In lots # 1 to # 4, when the parts assembling work for lot # 4 is completed, the parts on the towed carriage 72 (721) are used up, so there is no problem.

  In lot # 5, for every 30 production units, 120 parts of part numbers “5555-SDA” and “12345-SDA” are placed in the individual container 8 for each lot, and one towed truck 72 It is loaded and carried out. At the end of the part assembling work of lot # 5, only 30 parts are used, so 90 parts of each of the two part numbers remain and are in stock on the line side 5a.

In lots # 6 to # 8, two parts of 90 parts having a part number “5555-SNE” and 90 parts having a part number “12345-SDA” are used in succession. The part number “12345-SDA” is used because there are 90 stocks of the lot # 5 on the line side 5a. For this reason, the towed truck 72 (723) requires a total of 90 parts corresponding to the part number “5555-SNE” by assembling lots # 6 to # 8. 120 of the individual charges are loaded into the individual container 8 and loaded.
At the end of the part assembly work for lot # 8, 90 stock parts with the part number “5555-SDA” on the towed truck 72 (722) at the time of lot # 5 and the current towed truck 72 (723) No. “55555-SNE” in stock part 30 is in stock on the line side 5a.

  In this way, in the comparative example, since the unit 2 is unloaded in units of 120, only the parts whose line side 5a is out of stock are to be supplied, so the supply timing varies. Since the lot range covering this is different, the operator needs to determine necessary parts from a plurality of carts 70 and take them out.

  The lot # 9 is divided into one lot, and 30 parts numbers “55555-SNE”, “33333-SNA”, and “12345-SDA” for one lot are used. The part number “5555-SNE” is used because there are 30 lots # 8 in stock on the line side 5a. The part number “5555-SDA” has 90 stocks of the lot # 5 on the line side 5a, but since it is not used in the current lot # 9, it continues to be stocked on the line side 5a.

For this reason, in assembling lot # 9, 30 parts for each part number “33333-SNA” and “12345-SDA” are required for each lot. Are loaded into the individual container 8 and loaded onto one towed truck 72 (7224) for unloading.
At the end of the part assembling work of lot # 9, 90 stock parts of the part number “5555-SDA” on the towed truck 72 (722) at the time of lot # 5 and the current towed truck 72 (724) ) Ninety of the respective stock parts of the upper part number “33333-SNA” and part number “12345-SDA” are in stock on the line side 5a.

The lots # 10 to # 12 require 90 parts of the same part numbers “5555-SNE” and “12345-SDA” as the lots # 6 to # 8. The stock is different. That is, since the towed truck 72 (725) on which the parts to be used when assembling the parts of the lots # 10 to # 12 are loaded requires a total of 90 parts of the part number “5555-SNE” for three lots. , 120 pieces of the supplier 2 of the part number are put in the individual container 8 and loaded on one towed truck 72 (725).
At the end of the part assembling work for lot # 12, 30 stock parts with the part number “5555-SNE” on the towed carriage 72 (725) this time and the towed carriage 72 (722) for the lot # 5. 90 inventory parts of the upper part number “5555-SDA”, 90 inventory parts of the part number “33333-SNA” on the towed truck 72 (724) at the end of the part assembly work of the lot # 9, Becomes the stock of the line side 5a.

  In the lot # 13, 15 parts of the part number “5555-SNE”, 15 parts of the part number “5555-SDA”, and 30 parts of the part number “12345-SDA” are used. When the parts used in the lot # 13 are supplied to the line side 5a by the towed carriage 72 (726), the parts on the line side 5a are in stock, so the parts corresponding to the difference are required. For this reason, the towed truck 72 (725) on which the parts to be used when assembling the parts of the lot # 13 need 30 parts of the part number “12345-SDA” in total for one lot. 120 parts of the part 2 supplier 2 are placed in the individual container 8 and loaded onto one towed truck 72 (726).

At the end of the part assembling work for lot # 13, 15 stock parts with the part number “5555-SNE” on the towed truck 72 (722) at the time of lot # 5 and the towed car at the time of lot # 2 72 (722) part number “5555-SDA” 75 inventory parts, lot # 4 towed truck 72 (724) part number “33333-SNA” inventory part, lot # 6 90 parts of the part number “12345-SDA” on the towed truck 72 (726) of the car and the line side 5a are in stock, and 4 towed trucks 72 (722, 724, 725, 726) are in line. Mixed in the same supply location on the side 5a.
For this reason, since four types of parts are mixed as stock in the same supply place on the line side 5a, there is a possibility of erroneous assembly. Moreover, since the four towed carriages 72 (722, 724, 725, 726) are mixed in the supply place, the empty space on the line side 5a is narrowed.

In the lots # 14 to # 16, 90 parts having a part number “5555-SDA” and 90 parts having a part number “12345-SDA” are used. When the parts used in the lots # 14 to # 16 are supplied to the line side 5a by the towed carriage 72 (727), the parts corresponding to the number obtained by subtracting the stock of the line side 5a are required.
For this reason, the towed truck 72 (727) on which the parts used for assembling the parts of the lots # 14 to # 16 are loaded with 15 parts of the part number “5555-SDA” for three lots. 120 of the individual charging number of the supplier 2 of the part number is put in the individual container 8 and loaded on one towed truck 72 (727) to be carried out.

  At the end of the part assembling work of lot # 16, 15 stock parts with the part number “5555-SNE” of the towed truck 72 (722) at the time of lot # 5 and the towed truck 72 (at the time of lot # 7) 727) part number “55555-SDA” 105 stock parts and lot # 4 towed truck 72 (724) part number “33333-SNA” stock parts 90 stocks in line side 5a Since the four towed trucks 72 (724, 725, 726, 727) remain in the state where the parts are loaded at the same supply location on the line side 5a, the line side 5a is congested.

  Thus, in the comparative example, although the refilling operation can be eliminated by using the individual container 8 from the supplier 2 as it is and the refilling operation of the parts is not performed, a plurality of types similar to the supply location of the line side 5a can be eliminated. Since there are parts, there is a possibility of incorrect assembly. Furthermore, since a large number of towed trucks 72 coexist in the supply location, there is a problem in that it is an obstacle during assembling work or supply of other trains.

<Effect of demand reback of the present invention on the comparative example>
In contrast to this comparative example, as shown in FIG. 6, the present invention can reduce the man-hours for the refilling work by collecting the shipments as much as possible. Further, since the cart 70 on which the surplus parts are placed can be eliminated, the empty space on the line side 5a can be widened and refreshed. Furthermore, since the towed carriage 72 is also empty when each part is used up in the assembly line 6, smooth collection of the empty carriage and supply of necessary parts are performed in a timely manner, and the line side 5a is not crowded. Thus, the carriage 70 can be carried in and out. Thereby, since the space of the line side 5a is refreshed, it is possible to improve productivity and workability and to reduce the number of workers for exchanging the carriage.

≪Train consolidation decision≫
With reference to FIG. 9, the connection determination in the case of connecting the carriage 70 to form a train will be described.
In FIG. 9, “Car #” 1 to 7 are the towed trucks 72.
“Individual” of “coefficient” is a truck coefficient (supply means coefficient) of the total length of each trailer 72 when the coefficient of the total length of the trailer 72 to be a reference is 1.0. The towed carriage 72 has various types and lengths as indicated by “individual” numbers 1.0 to 1.5.
The “coefficient” “cumulative” is the cumulative total of “individual” values obtained by connecting the towed trucks 72 to form a train. The connectable coefficient (maximum connection coefficient) is an allowable limit length of one train that can pull the towed carriage 72 at a time, and is 6.0, for example. In this case, the train connection condition is that the “individual” values of the towed trucks 72 to be connected are added, and the “total” is within 6.0. The connectable coefficient (maximum connection coefficient) is the maximum length (maximum number of connected units) calculated from the width of the aisle 5b on which the train travels and the size of the curve, and varies depending on the travel location.

#A of “zone” is a parts supply destination (delivery zone) that supplies parts loaded on the towed truck 72, and the towed truck 72 of the connected train always has the parts loaded on the same zone. 70.
“Locations” 001 to 034 are parts supply locations (line stock areas) in the factory 5 and indicate parts supply destinations (addresses).
“Order” 1 to 7 indicate delivery priorities assigned to the locations. The closer the distance from the parts management base 4, the higher the priority.
A quantity of 30 to 120 is a quantity for supplying parts.

  “Time” 14:20, 14:27, 14:28, 14:32, 14:33, 14:34, 14:36 indicate the supply time for supplying the parts. “Time” 14:35, 14:42, 14:43, 14:47, 14:48, 14:49, 14:51 is the maximum allowable supply time, and is a time obtained by adding the delay time to the supply time. It is. The delay possible time is a time (15 minutes) arbitrarily set for each of the zones #A to #C in consideration of the inventory consumption progress of the line side 5a. In other words, the parts may be supplied to the location between the supply time shown in the table and the maximum allowable supply time.

As shown in FIG. 9, when one train is assembled, the towed truck 72 for the same destination zones #A to #C is arranged in order from the earliest scheduled date and time to the first carriage 70 (towed truck 72). Trains are grouped and grouped within the range of the delay possible time zone and the maximum coupling coefficient.
The train does not cut the line inventory by being within the range of the delay time of the first towed truck 72, and the schedule date and time of the last towed truck 72 is set as the representative schedule, so that the line side 5a Trains are assembled at the optimal timing when the stock is scarce.

According to the dynamic train build condition of the train, the schedule date of the cart 70 connected to the same train must be within the range of the delay time zone of the cart 70 having the earliest schedule date. A truck 70 (towed truck 72) scheduled before the allowable supply time of 14:35 is a target of train combination.
The train says, “The connection length of the carriage 70 is within the maximum length that the train can operate. As a result of the dynamic train build conditions, the number of trucks can be assembled in which the cumulative coupling coefficient of the trucks 70 is 6.0 or less.
Based on these conditions, the train composed of the carriage # 1 becomes the five towed carriages 72 up to the carriage # 5 (determined by the connectability factor), and the “train representative schedule date and time are linked to the same train. The train's representative schedule is 14:33 of the carriage # 5 due to the dynamic train build condition of “adopting the latest schedule date and time among the scheduled dates and times of the carriage 70”.

  In this way, the present invention conveys each towed truck 72 connected to one train at a timely time when the carriage 70 is not crowded, and a required number of parts before the required time. Can be supplied by.

≪Regarding retraining of unfinished carts≫
With reference to FIG. 10, the retrain combination of the cart 70 that has not started work (no actual data) will be described. In FIG. 10, vertical “# 100 to # 124” are lot numbers of products flowing on the assembly line 6. The lot “8-1” is a group of automobiles manufactured under the same conditions in the assembly line 6 and indicates that there are 8 lots on the assembly line 6 in the normal time zone. 6:28 to 20:20 next to FIG. 10 indicates time. E of lot numbers # 104 to # 113 and E ′ of lot numbers # 114 to # 123 indicate a lot in the calculation target range for one time.

Of the previous calculation target range (E), the latter half (F) after # 107 does not satisfy the entire line with only the lot in the calculation target range, so the number of parts to be supplied and the parts are loaded at the same timing. The number of towed carriages 72 to be reduced is reduced, and a train with poor connection efficiency is created.
In the current calculation target range (E '), the first half (G) before # 120 does not satisfy the entire line with only the lot in the calculation target range. The number of towed carriages 72 to be reduced is reduced, and a train with poor connection efficiency is created.

The towed trucks 72 existing in the parts (F, G) where the coupling efficiency is deteriorated are set as the same calculation target range, and the calculation processing is performed under normal calculation conditions in which the lot of the calculation target range satisfies the entire line. The improvement of the supply instruction content of the portion (H) where the connection efficiency has been deteriorated by performing this is called a train reorganization process.
Originally, in order to perform calculation processing of data having different calculation target ranges as the same calculation target range, it is necessary that the data contents of the other parties to be combined have already been determined.
Therefore, the logic always calculates the second half of the previous calculation target range and the first half of the current calculation target range as the targets of the reorganization process.

When the calculation is performed in units of 10 lots (“114” to “123”), the calculation result for the “119” lot or earlier (the portion G in FIG. 10) is a train set in the cart 70 of less than 8 lots. , The connection efficiency deteriorates.
In this case, the truck 70 that always supplies parts for the eight lots of cars on the assembly line 6 is taken as a target by pulling down the part of the previous instruction train that has not been started and re-importing it as the target of the train assembly. Since trains can be assembled, train connection efficiency can be improved.

≪Configuration of supply plan creation system≫
As shown in FIG. 8, the supply plan creation system 1 supplies parts to a line side 5a in an assembly line 6 in which a plurality of parts are assembled to continuously produce different types of automobiles (products) in predetermined lot units. It is a system that creates a supply work plan for The supply plan creation system 1 mainly includes a component supply work plan creation device 10 to be described later, an input device 18, an output device 19, a CPU (not shown), and a storage device (not shown).

≪Configuration of parts supply work plan creation device≫
As shown in FIG. 1 or FIG. 8, the parts supply work plan creation device 10, based on the production plan information 112 of parts to be assembled in the assembly line 6 of the factory 5, stores the parts in the line inventory areas 070 to 070 of the assembly line 6. 183 (see FIG. 5) is a device for creating a parts supply work plan by the towed carriage 72 (supply means 7) to be supplied to, for example, a terminal device such as a personal computer. The parts supply work plan creation device 10 is functionally divided into a demand repack unit 10A that performs a demand repack function, a dynamic train build unit 10B that performs a dynamic train build function, and a cart 70. A train reorganization setting unit 10C that performs the function of train reorganization is mainly configured. The parts supply work plan creation device 10 synchronizes with the assembly line 6 and calculates the sorting work time for delivering the parts to the assembly line 6, thereby suppressing the excess inventory of the assembly line 6 without reducing the supply efficiency of the parts. It is possible to simplify the line side 5a and improve productivity and workability.

  The demand / repack unit 10A of the component supply work plan creation device 10 includes a product assembly information storage unit 11, a supply means information storage unit 12, and a supply plan creation unit 14, which will be described later. The dynamic train build unit 10B includes a calculation control information storage unit 15 and a supply schedule setting unit 16, which will be described later. The train reorganization setting unit 10C includes a recalculation target setting unit 17 described later.

The supply means 7 (see FIG. 4) is a device that loads parts and supplies them to the line stock areas 070 to 183 (see FIG. 5) of the parts. For example, the supply means 7 is the towed carriage 72 of the carriage 70.
The conveying means is an apparatus that conveys the towed carriage 72 of the supplying means 7 to the line stock areas 070 to 183 for supplying parts, for example, the towing carriage 71.

<Configuration of product assembly information storage unit>
As shown in FIG. 8, the product assembly information storage unit 11 produces part identification information 111 for identifying and managing parts, the lot size of each product flowing on the assembly line 6, the production order of each product, and the number of lots. Production plan information 112 planned with time, production progress information 113 that grasps the production amount of the automobile (product) that actually flows through the assembly line 6 with production time, process information 114 to be described later, and component configuration information 115 to be described later And a line inventory area information 116 to be described later.

  The part identification information 111 is information such as the name, part number, and quantity of the parts to be supplied that are individually packaged, and is barcode-managed. The contents of the packaging specification of packaging parts can be grasped through the barcode.

The production plan information 112 is vehicle production information such as the production type, the number of vehicles produced, and the production date and time of vehicles produced on the assembly line 6.
The production progress information 113 is transmitted to and stored in the product assembly information storage unit 11 as needed from the assembly progress information and the line control (GALC (Global Assembly Line Control)) information of the assembly of the parts to the vehicle body in the assembly line 6. The Therefore, the production progress information 113 and the current production information can be known from the production progress information 113.

The process information 114 is information on work processes performed in each of the line stock areas 070 to 183 (see FIG. 5) of the assembly line 6.
The parts configuration information 115 is information on parts to be assembled in the automobile, and is a data base including a parts configuration and a list of parts when assembling the parts (BOM (Bills of Materials)) and a parts table. The address to which the component is supplied is stored.

  The line inventory area information 116 is information of each line inventory area 070 to 183 (see FIG. 5) of the assembly line 6, and includes a zone master 117 and a location master 118.

  The zone master 117 includes the position information of the zones #A to #C of the line to which the parts supply destination zones #A to #C (see FIG. 5) belong, and the parts supply destination zones #A to #C. The time required for transporting the train (supply means 7) to #C (access time to zones #A to #C), the maximum delay time for the train supplied to zones #A to #C, etc. are stored. Has been.

The location master 118 includes location information of locations such as lines, zones #A to #C, passages, etc. to which the location of the parts supply destination (line stock areas 070 to 183) belongs, and the location of the parts supply destination from the parts management base 4. The delivery sequence number assigned according to the distance up to and the total number of vehicle bodies (body NO) from when the vehicle body to be manufactured reaches the location of the parts supply destination after the vehicle body is lined on the assembly line 6 are stored. .
In addition, the delivery order number determines the connection order (far → near) when the towed truck 72 is connected to the train depending on the size of the number. The number of vehicle bodies is used to calculate the supply instruction time starting from the line-on date / time to the assembly line 6.

<Configuration of supply means information storage unit>
As shown in FIG. 8, the supply means information storage unit 12 includes supply means identification information 121 for grasping the classification of the loaded parts loaded on the towed carriage 72 of the carriage 70, and a loading allowance for grasping the allowable number of loaded parts. This is a database in which numerical information 122 is stored.
The supply means identification information 121 includes information on the parts to be loaded on which tow truck 72 and which parts to be loaded, identification information of each carriage 70, model information of various carriages 70, and parts by the carriage 70. This is cart master information including a connection coefficient of a train state in which the carriage 70 is connected to one unit of supply operation. The connection coefficient is a coefficient that is defined based on the length of one standard towed truck 72 and is set according to the length of each truck 70 in order to determine the total length of the connected trains. .
The loading allowable number information 122 is a loading allowable number such as the maximum number of individual containers 8 that can be loaded in each type of towed carriage 72 or the maximum number of components that can be loaded.

<Configuration of supply plan creation section>
The supply plan creation unit 14 is a device that identifies the parts to be loaded on the towed truck 72 (supply means 7) and supplied to the line side 5a, and formulates the quantity and supply time of the parts, and supplies the number of supply parts. A train organization is calculated in which the used quantity of the plurality of types of used parts obtained in 144 is loaded and connected to the towed truck 72 (supply means 7), and the parts are placed in the line stock areas 070 to 183 (see FIG. 5). Create a supply plan for supply. The supply plan creation unit 14 includes a lot use number calculation unit 141, a continuous lot number calculation unit 142, a minimum continuous lot number calculation unit 143, a supply component number calculation unit 144, and a supply instruction time calculation unit, which will be described later. 145, allowable supply time calculation means 146, supply means group selection section 147, transport preparation start data storage means 148, reorganization reference time setting means 149, calculation control information storage section 15, and supply schedule setting section 16. , Is electrically connected to.

  In addition, the supply plan creation unit 14 creates a supply plan for each plan target range that is divided into ranges with time, days, and other predetermined periods, and has a towed truck 72 (supply) having a supply instruction time within the plan target range. The means 7) is selected as the supply plan creation target supply means. In addition to the supply plan creation target supply unit, the supply plan creation unit 14 sets a supply instruction time that is before the plan target range to which the supply plan creation target supply unit belongs and is later than the reorganization reference time. A supply plan is created by incorporating the towed truck 72 (supply means 7).

Based on the production plan information 112 and the part configuration information 115, the lot usage number calculating means 141 is loaded on the towed carriage 72 (supply means 7) and accommodated in predetermined line stock areas 070 to 183 (see FIG. 5). This is a calculation device that specifies used parts and obtains the required number of parts to be used for each lot in units of lots.
The continuous lot number calculating means 142 is a calculation device that calculates the number of lots in which a plurality of types of used parts are used continuously.

  The minimum continuous lot number calculating means 143 is one line in the line stock areas 070 to 183 loaded on the supplying means 7 among the respective continuous lot numbers of the plurality of types of used parts obtained by the continuous lot number calculating means 142. This is a calculation means for obtaining the minimum number of continuous lots among the combination of parts supplied to the stock areas 070 to 183. The number of continuous lots calculated by the minimum continuous lot number calculating means 143 becomes the load capacity allocated to one towed truck 72 constituting the train.

The supply component number calculation means 144 is a calculation device that adopts the number of continuous lots equal to or less than the minimum lot number and obtains the number of used parts of a plurality of types of used components that covers the selected number of continuous lots.
The supply instruction time calculation means 145 obtains the supply instruction time of the cart 70 (supply means 7) by determining which parts and how many parts supply locations (line stock areas 070 to 183) are required to supply the parts. A calculation device for calculating.

  The supply allowable time calculation means 146 adds the maximum delay time (for example, 15 minutes) that is a surplus time to the necessary supply instruction time of the component calculated by the supply instruction time calculation means 145 and supplies it. It is a calculation device for calculating an allowable time.

  The supply means group selection unit 147 is a device that calculates and selects the towed carriage 72 that is connected to and integrated into one train. This supply means group selection unit 147 supplies each supply in the towed truck 72 (supply means 7) to be supplied to the line stock areas 070 to 183 (see FIG. 5) in the same zones #A to #C (see FIG. 5). Arranged in order from the instruction time, the towed carriage 72 with the latest supply instruction time does not exceed the supply allowable time for the towed carriage 72 with the earliest supply allowable time, and the overall connection length is within the allowable connection length. The combination of the trolley | bogie 70 (supply means 7) is selected so that it may become.

  The transfer preparation start data storage unit 148 stores transfer preparation start data for specifying the towed carriage 72 (supply unit 7) that has started transfer preparation based on the supply plan. The transport preparation start data storage means 148 is connected to the supply plan creation unit 14.

  The reorganization reference time setting unit 149 is a calculation device that sets the time for reorganizing the train. The reorganization reference time setting unit 149 refers to the transfer preparation start data storage unit 148 to grasp the supply instruction time for the latest transfer preparation start data storage unit 148, and adds a grace time to the supply instruction time to perform the reorganization. Set the reference time.

<Configuration of calculation control information storage unit>
As shown in FIG. 8, the calculation control information storage unit 15 is a database that stores calculation control information 151.
The calculation control information 151 includes train information such as a train length, a maximum connection coefficient of the carriage 70, a reorganization buffer, and the like.

<Configuration of supply schedule setting unit>
The supply schedule setting unit 16 is a calculation device that sets a transport schedule for a dynamic train / build train, and includes a supply schedule determination unit 161. The supply schedule setting unit 16 sets the supply instruction time for the carriage 70 (supply means 7) having the latest supply instruction time among the plurality of connected trucks 70 (supply means 7) as the supply representative time.
The supply schedule determination means 161 is a calculation device that determines the supply time at which each towed truck 72 constituting the train supplies to each of the line inventory areas 070 to 183 (see FIG. 5).

≪Configuration of recalculation target setting section≫
The recalculation target setting unit 17 is a device that sets the order of the towed truck 72 and the train reorganization. The recalculation target setting unit 17 includes a recalculation target extraction unit 171 that extracts an object to be recalculated.

≪Configuration of input device≫
The input device 18 is a device that inputs information generated by an input operation to the component supply work plan creation device 10, and includes, for example, a keyboard, a mouse key, a barcode reader, a reading key for reading an image such as a component slip, An instruction key such as a transmission key for instructing transmission is provided. The input device 18 is arranged and online on the trailer yard 3, each area of the parts management base 4, and the line side 5 a in the factory 5. Each data input by the input device 18 is stored and updated by the component supply work plan creation device 10.

≪Configuration of output device≫
The output device 19 is a device for recognizing and outputting a component supply plan document and various information output from the component supply work plan creation device 10, and displays the information on a screen and prints the information. It is a printer. The output device 19 is arranged and online on the trailer yard 3, each area of the parts management base 4, and the line side 5 a in the factory 5.

[Operation]
Next, the operation of the supply plan creation system 1 according to the present invention will be described with reference to FIGS. 1 and 11 to 13 mainly.

<Demand repacking>
First, the demand repacking process will be described with reference to FIG. 1, FIG. 8, and FIG.
First, the operator determines an arbitrary lot number range within the planning target range, and operates the input device 18 to input the arbitrary lot number. The component supply work plan creation device 10 acquires information on the carriage 70 (supply means 7) from the supply means identification information 121 recorded in the supply means information storage unit 12 (step S1). Next, the maximum load number of each towed truck 72 (supply means 7) is acquired from the allowable load number information 122 of the supply means information storage unit 12 (step S2).

  Subsequently, the parts supply work plan creation device 10 acquires the production model and the number of lots of the next lot from the production plan information 112 stored in the lot usage number calculation means 141 of the supply plan creation unit 14. Furthermore, the part supply work plan creation device 10 acquires the parts and the number of parts used for the production model of the next lot from the part configuration information 115 of the product assembly information storage unit 11 (step S3).

  Next, the parts supply work plan creation device 10 uses the continuous lot number calculation means 142 of the supply plan creation unit 14 to use the same number of parts as the parts of the previous lot, and the number of parts to be pulled is towed by the next lot. The number of parts and the number of lots are accumulated within a range that does not exceed the maximum load number of the carriage 72 (supply means 7), and written in the calculation data (step S4).

  Next, the parts supply work plan creation device 10 causes the minimum continuous lot number calculation means 143 of the supply plan creation section 14 to sort and read the calculation data in the order of “supply means / number of lots”, and the same towed cart In 72 (supply means 7), the number of lots of parts with the smallest number of lots to be covered is determined as the number of loaded items (step S5).

  Subsequently, when the number of lots exceeds the number of loaded parts in the parts to be loaded on the same towed truck 72 (supply means 7), the number of lots and the number of parts exceeding the number of parts are subtracted by the supply part number calculation means 144. To determine the number of parts supplied. In this case, the coverage is unified to the minimum number of lots, and the timings at which the parts in the line inventory areas 070 to 183 are consumed are matched. That is, the parts loaded on each towed truck 72 are used at the same timing for each towed truck 72 (step S6).

The demand repack can reduce the refilling man-hours by creating the supply work plan and supplying the parts so that the packaging of the parts can be packed as much as possible.
Moreover, since there is no cart 70 on which extra parts that are not used up are left over, it is possible to select and take derivative parts from a plurality of carts 70, and to eliminate frequent cart replacement, and to save space on the line side 5a. Since it can be used cleanly and efficiently, productivity and workability can be improved.
In addition, since the empty cart 70 can be smoothly collected along with the delivery at the time of use up, the cart 70 can be used in an efficient use cycle.
Along with this, the number of trucks 70 loaded with parts on the line side 5a, the number of individual containers 8 containing parts, and the number of parts can be reduced, thus preventing erroneous assembly due to wrong parts and improving quality. Can be made. Further, by reducing the carts 70 arranged on the line side 5a, it is possible to reduce the work man-hours and the number of workers for performing the exchanging work of the carts 70 to the minimum necessary number.

<Dynamic train build processing>
Next, the dynamic train build process will be described with reference to FIGS. 1, 8, and 12. FIG.
First, the parts supply work plan creation device 10 uses the production plan information 112 and production progress information 113 in the product assembly information storage unit 11 to determine the line-on date and time of the product (automobile) that has been line-on to the assembly line 6 and the production order ( Information such as supply order). Next, the time obtained by “number of units × line tact” from the production order of line-on to the production order of parts to be integrated is adjusted from the line-on time, and the supply instruction time calculation unit 145 and the allowable supply time calculation unit 146 The supply instruction time and delay possible time range (supply date + buffer time) of the towed truck 72 (supply means 7) are calculated and acquired (step S10).
Here, the “buffer time” is a time that may be delayed, and the line inventory in the line inventory area 070 to 183 is not cut in accordance with the consumption progress of the parts in the line inventory area 070 to 183 (see FIG. 5). It is a supply grace time provided to determine the range that can be supplied in

  Next, the parts supply work plan creation device 10 acquires the maximum connection coefficient of the carriage 70 (supply means 7) from the calculation control information 151 of the calculation control information storage unit 15 (step S11).

Next, the parts supply work plan creation device 10 sorts the calculation data in the order of the zone / supply instruction time, and arranges the supply instruction times for supplying the parts for each of the zones #A to #C (see FIG. 5) in the order of time. get. Subsequently, the coefficient of the towed truck 72 (supply means 7) is obtained from the supply means identification information 121 of the supply means information storage unit 12, and the supply means coefficients are arranged in the order of the supply instruction time in the same zone #A to #C. Accumulate. Further, the same towed carriage 72 (supply) is within a range where the accumulated supply means coefficient does not exceed the maximum coupling coefficient and does not exceed the delay possible time range of the leading towed truck 72 (supply means 7). As a means 7), the train combination of the cart 70 (supply means 7) to be connected is determined (step S12).
In this step S12, the length of the train that can be operated by transporting the train once, or the combination of connection of the towed carriage 72 (supply means 7) that can be supplied at a timing at which the supply of parts can be completed without delaying the supply time Decide.

Subsequently, the supply means group selection unit 147 sorts and reads the calculation data in the descending order of the transportation orders set in the line inventory areas 070 to 183 (see FIG. 5), and the towed truck 72 ( The connection order of the supply means 7) is determined (step S13).
In this step S13, the order of connection of the towed trucks 72 in the train is assigned in the reverse order of delivery. That is, the order of connection of the towed truck 72 is issued in the order of disconnecting from the train. For this reason, when parts are supplied by the carriage 70 constituting the train, the parts are delivered in the closest order in the same zones #A to #C (see FIG. 5). On the way back, the tow truck 71 returns to the parts management base 4 while collecting the empty towed truck 72 loaded with empty individual containers 8.

  Next, the supply schedule determination means 161 sorts and reads the calculation data in descending order of the supply instruction time, and determines the supply instruction date of the towed truck 72 (supply means 7) (step S14). In step S <b> 14, the latest dispatch date / time among the towed trucks 72 belonging to the same train is adopted as the dispatch date / time of the towed truck 72. That is, the parts supply of the towed truck 72 is prevented from being accelerated with respect to the parts consumption in the line stock areas 070 to 183 (see FIG. 5).

  In the dynamic train build, such a supply work plan is created, and parts are supplied by the towed truck 72 (supply means 7), so that the target number of connectable trucks 70 is maximized and aggregated. Therefore, the number of deliveries can be reduced.

<Train reorganization process>
Next, train reorganization processing will be described with reference to FIGS. 8 and 13.
First, the component supply work plan creation apparatus 10 shown in FIG. 8 acquires a buffer time from the calculation control information 151 stored in the calculation control information storage unit 15 (step S20). Here, the buffer time is provided in order to prevent the actual plan from being stopped or restarted by invalidating the latest plan when canceling the parts supply plan linked to the actual data updated in real time. This is the grace time for recalculation.

  Subsequently, the component supply work plan creation device 10 reads the last data of the component supply plan for which there is a record from the supply plan creation unit 14 and obtains the latest worked supply instruction time. Further, the buffer time is added to the latest completed supply instruction time from the recalculation target extraction means 171 to determine the reference date and time for train reorganization (step S21).

  A parts supply plan having a supply instruction time after the train reorganization reference date and time is read and added to the calculation data before being determined as the train reorganization and updated (step S22). The old part supply plan data subject to train reorganization is deleted, and new part supply plan data is recreated from the calculation data (step S23).

  By creating a parts supply work plan in this way and reorganizing the train to supply parts, the number of carts 70 that can be connected can be maximized and consolidated, thereby reducing the number of deliveries. be able to.

[Modification]
The present invention is not limited to the above-described embodiments, and various modifications and changes can be made within the scope of the technical idea, and the present invention extends to these modifications and changes. Of course.

  In the above-described embodiment, the cart 70 (the towed truck 71 and the towed truck 72) is described as an example of the supply unit 7. However, the supply unit 7 includes a large number of individual containers 8 containing components at a time. What is necessary is just to have the function which can be conveyed, for example, a belt conveyor may be sufficient.

  In the above embodiment, the supply part number calculating unit 144 has adopted that a continuous lot number equal to or less than the minimum lot number is adopted, and the number of used parts of a plurality of types of used parts that covers the adopted continuous lot number is obtained. However, the present invention is not limited to this. For the number of lots supplied to the line side 5a, for example, the upper limit of the number of lots is determined in advance from the method of the number of continuous lots less than the minimum number of lots, the shape and size of parts, the size of the route on which the train travels, etc. It may be the way to do it.

Next, determination of the upper limit of the number of supplied parts will be described.
When the same parts are used continuously, the number of supplied parts is calculated from the number of consecutive lots, and the upper limit range is determined by the setting contents of the master data.
The setting contents of the master data include the number of parts accommodated per container, the number of containers loaded per towed carriage 72 (= the number of parts allowed to be loaded), and one line inventory area 070 to 183 in the line side 5a. There are the number of towed trucks 72 (the number of carts) that can be supplied.

The number of parts accommodated in one container is determined by the number of parts that can be accommodated in the container according to conditions such as the size, weight, and shape of the parts.
The number of containers loaded per towed truck 72 (= the number of parts allowed to be loaded) is determined by the number of parts that can be loaded on the towed truck 72 according to conditions such as the size, weight, and shape of the container.
The number of carts that can be supplied to one line stock area 070 to 183 in the line side 5a is the number of carts that can be simultaneously placed in the line stock area 070 to 183 of the line side 5a as a towed carriage 72 containing unused parts. It is determined according to conditions such as the space in the line stock area 070 to 183 on the line side 5a and the usage status of parts.

The upper limit A of the number of parts to be supplied, P is the number of parts accommodated per container, N is the number of containers loaded per cart (towed truck 72), and N is one line inventory area 070 to 183 in the line side 5a. Assuming that the number of carts that can be supplied is C, the upper limit A of the number of parts to be supplied is the following formula: A = P × N × C
Is calculated by

DESCRIPTION OF SYMBOLS 1 Supply plan preparation system 5 Factory 5a Line side 6 Assembly line 7,72 Supply means 11 Product assembly information storage part 12 Supply means information storage part 14 Supply plan preparation part 16 Supply schedule setting part 070-183 Line stock area 71 Conveyance means 111 Parts identification information 112 Production plan information 113 Production progress information 121 Supply means identification information 122 Load allowable number information 141 Lot use number calculation means 142 Continuous lot number calculation means 143 Minimum continuous lot number calculation means 144 Supply parts number calculation means 145 Supply instruction time Calculation unit 146 Allowable supply time calculation unit 147 Supply unit group selection unit 148 Transfer preparation start data storage unit 149 Reorganization reference time setting unit A # to C # zone

Claims (5)

A supply plan creation system for assembling a plurality of parts and supplying the parts to the line side in an assembly line for continuously producing products of different models in a predetermined lot unit,
A line inventory area that is provided on the line side and that accommodates parts to be assembled in each process of the assembly line in predetermined sections,
Supply means for loading the parts and storing them in a line inventory area of the parts;
Conveying means for conveying the supply means to the line inventory area;
Parts configuration information that is a list information of parts to be assembled to the product, lot size of each product flowing on the assembly line, production order information of each product, and production plan information that plans the number of lots together with production time A product assembly information storage unit to store;
A supply means information storage unit for storing supply means identification information for grasping the classification of the loaded parts, and load capacity number information for grasping the allowable load number of the load parts;
A supply plan creation unit that identifies parts to be loaded on the supply means and formulates the quantity and supply time of the parts;
The supply plan creation unit
Based on the parts configuration information and the production plan information, the used parts loaded on the supply means and accommodated in the predetermined line stock area are specified, and the number of used parts used for each lot is obtained. Usage calculation means;
A continuous lot number calculating means for obtaining the number of lots in which the plurality of types of used parts are used continuously;
Of the continuous lot numbers of the plurality of types of used parts obtained by the continuous lot number calculating means, the smallest continuous lot among the combinations of parts loaded on the supply means and supplied to the one line stock area Means for calculating the minimum number of consecutive lots for obtaining the number;
Adopting the number of continuous lots less than or equal to this minimum lot number, supply parts number calculating means for obtaining the number of used parts of the plurality of types of parts used to cover the number of consecutive lots adopted,
A supply plan creation system for creating a supply plan for loading the used quantities of the plurality of types of used parts obtained by the supply part number calculation means onto the supply means and supplying them to the line stock area. The assembly line is divided into a plurality of zones,
The product assembly information storage unit further stores production progress information that grasps the production amount of the product that actually flows through the assembly line together with the production time,
The supply plan creation unit
Supply instruction time calculating means for calculating a supply instruction time of the supply means;
Supply allowable time calculation means for calculating a supply allowable time by adding a delay possible time to the supply instruction time;
Arranged in order from the supply instruction time in the supply means supplied to the line inventory area in the same zone, the supply means of the latest supply instruction time does not exceed the supply allowable time for the supply means of the earliest supply allowable time And a supply means group selection section for selecting a combination of the supply means so that the overall connection length is within the allowable connection length,
2. The supply plan creation system according to claim 1, wherein the transport unit connects a plurality of supply units selected by the supply unit group selection unit and transports them to the line inventory area. The conveying means is
A plurality of supply means selected by the supply means group selection unit are connected in series from the head to the tail, and the order from the closest to the far side of the line stock area to be supplied as viewed from a predetermined parts management base 3. The supply plan creation system according to claim 2, wherein the nearer supply means is connected to the tail and the farther supply means is connected to the head so as to be supplied at the top. The supply plan creation unit
The supply according to claim 3, further comprising a supply schedule setting unit that sets the supply instruction time for the supply means having the latest supply instruction time among the plurality of connected supply means as a supply representative time. Planning system. The supply plan creation unit creates the supply plan for each plan target range that divides time, day, target lot range, and other predetermined ranges,
Selecting the conveying means having a supply instruction time within the planning target range as a supply plan creation target conveying means;
Transport preparation start data storage means for storing data for specifying the transport preparation start transport means that has started transport preparation based on the supply plan;
By referring to the transfer preparation start data stored in the transfer preparation start data storage means, the supply instruction time for the latest transfer preparation start transfer means is grasped, and a reorganization reference time is set by adding a grace period to the supply instruction time. Reorganization reference time setting means,
In addition to the supply plan creation target transport means, a transport means that is before the plan target range to which the supply plan creation target transport means belongs and that has a supply instruction time after the reorganization reference time is incorporated. The supply plan creation system according to claim 3 or 4, wherein the supply plan is created.

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