JP2018169889A - Traceability management method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a traceability management method that can increase a traceability of component mounted on a product without causing as much cost as possible and an increase in work man-hours as much as possible.SOLUTION: A traceability management method for parts 10 mounted on a vehicle 14, is comprised of: a step of providing a passage 11 containing a plurality of parts 10 and a signboard 12 recording states of the parts 10 accommodated therein to an assembly line 13 for incorporating the parts 10; a step of arranging the signboard 12 possessed by the passage 11 containing the part 10 at the collection position when assembling the part 10 in the manufacturing process of the vehicle 14; a step of collecting the signboard 12 placed at the collection position at a specifying collection time; and a step where, on the basis of the parts information of the signboard 12 of the predetermined passage 11 and the collection time of the signboard 12, a range of the vehicle 14 that may have the parts 10 accommodated in the predetermined passage 11 is restricted.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a traceability management method for components mounted on a product.

  In the manufacturing process of a vehicle, a wide variety of parts are mounted on the vehicle through a plurality of processes. And, after the manufacture of the vehicle is completed, it may be necessary to specify a vehicle on which a specific part produced on a certain date and time is mounted. For example, if a part produced at a certain date and time is found to be defective and is recalled in the market, the range of vehicles on which the defective product may be mounted is limited. It is necessary to reduce the number of vehicles recovered from the vehicle as much as possible. Thus, traceability of components mounted on the vehicle becomes important when a recall occurs.

  However, in the past, there have been many cases where a management system that emphasizes traceability has not been sufficiently constructed for individual components mounted on a vehicle. In such a case, there is a problem that an excessive recall range is set with respect to a range of parts in which a defect is found. For example, if information is managed for each part only by the date the part was produced, the recall range was produced on that day even if there were only a few defective parts. Since all vehicles were used, there was a lot of waste in the cost of collection and the trouble of replacing defective parts.

  For such a problem, for example, there is a method for managing components by attaching an IC tag to each component (for example, Patent Document 1). In this case, by reading the IC tag with a tag reader, it is possible to read information such as the manufacturing year and manufacturing location of the component. In addition, a method of managing a component by providing a reading code such as a QR code (registered trademark) for each component and recording component information is also conceivable.

JP 2006-48101 A

  As described above, in the method of managing by providing an IC tag, a reading code or the like for each component, there is a problem that the cost of each component is increased by providing the IC tag or the like. In addition, in the vehicle assembly line, there is a problem that an IC tag is read and an operation of associating the vehicle with the component one-to-one occurs for all components (or all components requiring association). there were. In particular, in a vehicle, since a huge number of parts are mounted, it is not realistic to increase the cost and work man-hour for each part, and more preferable measures are required. .

  In view of the above, an object of the present invention is to provide a traceability management method capable of enhancing the traceability of parts mounted on a product without causing an increase in cost and an increase in work man-hours as much as possible.

  In order to solve the above-described problems, the present invention provides a component box having a recording material in which a plurality of the components are accommodated and the state of the accommodated components is recorded. In the assembly process for assembling the product, in the manufacturing process of the product, when assembling the component, placing the recording material of the component box containing the component at the collection position, and at the collection position. Based on the step of recovering the arranged recording material at a specific recovery time, the component information of the recording material of the predetermined component box, and the recovery time of the recording material, it was accommodated in the predetermined component box And a step of limiting the range of products on which the parts may be mounted.

  According to this configuration, the recording material attached to the component box is used for managing component information. As a result, the recording material attached to the parts box can be reused in the manufacturing process of the vehicle without increasing the cost of each part, so that the cost increase for managing part information is kept to a minimum. be able to. In addition, by managing part information for each of a plurality of parts housed in the same part box, it is relatively easier for traceability management than when managing individual part information. Work man-hours can be reduced.

  By the way, in the manufacturing process of a product such as a vehicle, conventionally, a signboard attached to a box for housing the part has been used for inventory management of the part. Parts information such as the number of parts accommodated in the box is recorded on the signboard. In the vehicle manufacturing process, the number of parts used in the assembly line is recognized by collecting the signboards after the parts are used, and the parts inventory is managed.

  In the present invention, in particular, by using the signboard as a recording material, it is possible to provide a recording material for managing component information without causing an increase in cost. In addition, part or all of parts inventory management and parts traceability management can be shared, so that the increase in the number of man-hours for traceability management can be minimized. .

  According to the present invention, by recording and managing component information on a recording material attached to a component box, it is possible to suppress cost increase and increase in the number of work steps as much as possible, and to improve the traceability of components.

It is the schematic which shows the process after components are produced until it mounts in a vehicle. It is a figure which shows the signboard attached to a mailing. It is a figure which shows the recall range with respect to one mailing. It is a figure which shows the process until the components integrated in an intermediate assembly are integrated in a vehicle. It is a figure which shows the recall range of the components integrated in an intermediate assembly. It is a figure which shows the recall range with respect to several mailings. It is a figure which shows an example of the process until components are conveyed to the assembly factory of a vehicle.

  As shown in FIG. 1, a part 10 is a part mounted on a vehicle as a product, and is produced at a parts factory K1 and incorporated into a vehicle at a vehicle assembly factory K2.

  The parts 10 are housed and transported in a box (parts box) for each predetermined quantity at the parts factory K1. In the illustrated example, every four parts 10 are sequentially accommodated in the boxes 11a, 11b, 11c,..., And these boxes are transported by the transport vehicle 30 to the assembly plant K2.

  At this time, a signboard (recording material) on which various pieces of information of the component 10 are recorded is attached to each box. In the illustrated example, signs 12a, 12b, and 12c are attached to the boxes 11a, 11b, and 11c, respectively.

  As shown in FIG. 2, reading information such as a barcode 31, a QR code (registered trademark) 32, and a character 33 that can be read by a reading mechanism such as a barcode reader is recorded on the signboard 12. In addition to this, a figure or the like indicating the information of the part may be described.

  The above read information provided on the signboard 12 is information relating to the part 10 (see FIG. 1), and specifically, the production location (part factory K1) and the destination (assembly factory K2) of the part 10 are accommodated. Information such as the name, the number, and the production date and time of the part 10 is described. Moreover, the production conditions and environmental conditions of the component 10 may be recorded. In addition, necessary information can be recorded as appropriate.

  As shown in FIG. 1, a vehicle assembly line 13 is provided in the assembly plant K2. In the assembly line 13, the vehicle 14 continuously flows in the direction of arrow A, and the vehicles 14 are sequentially assembled. The boxes 11a, 11b, 11c transported to the assembly factory K2 are provided to predetermined locations on the assembly line 13.

  The worker sequentially incorporates the components 10 into the vehicle 14 that flows continuously at a predetermined position on the assembly line 13. In the assembly line 13, a plurality of types of vehicles are assembled, and the parts 10 are not mounted on all the vehicles 14.

  When supplying the parts 10 to the assembly line 13, the parts 10 of the box 11a are used first, and when the parts 10 of the box 11a are used up, the parts 10 of the next box 11b are supplied. The parts 10 are used in order of the boxes 11a, 11b, and 11c. Then, for example, when using the first part 10 of the box 11a, the worker places (places) the signboard 12a attached to the box 11a at a predetermined collection position.

  Then, another worker collects all the signboards placed at the collection position every predetermined time. In the illustrated example, the signboards 12a and 12b are collected at the first collection time, and then the signboards 12c and 12d are collected at the next collection time.

  Each collected sign is read by the reading mechanism, and the information on the parts is read. Thereby, the number of parts 10 used in the assembly line 13 can be acquired as information. Then, by transmitting this information to the parts factory K1, as many parts 10 as used can be produced in the parts factory K1 and sent to the assembly factory K2 by the transport vehicle 30. In this way, the operator collects the signboard and reads the read information, so that the parts 10 can be produced as needed according to the number used and supplied to the assembly line 13. Therefore, the component 10 can be incorporated into the vehicle 14 in the assembly line 13 without causing the component to run out. The component information recorded on the signboard is read by the reading mechanism, or the operator reads the information printed on the signboard or recognizes the number of parts 10 used by the number of signboards. There may be.

  By the way, after the assembly of the vehicle is completed, it may be necessary to specify a range of the vehicle in which a specific part may be mounted.

  For example, in the market, when a plurality of parts 10 produced at a specific time are found to be defective, the vehicle 14 on which the defective parts 10 may be mounted is collected from the market or the customer. Then, there is a case where an operation of replacing the component 10 with a non-defective product is performed (so-called recall is performed). The narrower the vehicle range in which such a defective component 10 may be mounted (hereinafter referred to as the recall range in this embodiment) is preferable because the narrower the vehicle, the less the vehicle is collected. And in order to limit the recall range of a vehicle as much as possible, it becomes a subject to improve the traceability of the components mounted in the vehicle.

  In order to solve the above-described problem, the present embodiment employs a method for improving the traceability of parts by using the above signboard used for parts inventory management. Hereinafter, a traceability management method using a signboard will be described with reference to FIGS.

  As shown in FIG. 3, in the assembly line 13, the parts 10 accommodated in the boxes 11 a, 11 b, 11 c are sequentially assembled into the vehicle 14. When the first parts 10 of the respective boxes 11a, 11b, and 11c are used, the worker places the signs 12a, 12b, and 12c at the collection positions. In the illustrated example, after the collection time T0, the signboards 12a and 12b are placed at the collection position, and at the collection time T1, these signboards 12a and 12b are collected by another operator. Then, by reading the reading information of the signboards 12a and 12b, it is recorded that the collection time of the signboards 12a and 12b was the time T1, and the collection time T1 (with the signboards 12a and 12b respectively attached) The component information of the component 10 accommodated in 11b is associated. The above operation is an operation performed by an operator when the vehicle 14 is assembled.

  Here, after the assembly of the vehicle 14 is completed, it is assumed that only the part 10 accommodated in the box 11b is found to be defective (hereinafter, the part 10 accommodated in the box 11b is referred to as a defective part 10b). To do). Therefore, after the assembly of the vehicle 14 is completed, that is, after the assembly of the component 10 into the vehicle 14 is completed, the individual component 10 incorporated in the vehicle 14 can no longer be distinguished, and the signboard 12b associated with the defective component 10b. The range of the vehicle 14 in which the defective part 10b may be mounted is limited using the information of the recovery time T1.

  Each vehicle 14 flowing through the assembly line 13 has its production time and the like recorded, so that the time zone when the component 10 is incorporated into each vehicle 14 can be known. For this reason, the range of the vehicle 14 in which the defective component 10b is mounted can be limited by limiting the time zone when the defective component 10b is incorporated in the vehicle 14 or the like.

  First, by referring to the recorded information, it can be seen that the collection time of the signboard 12b was time T1. From this, it can be seen that the defective part 10b accommodated in the box 11b is mounted on the vehicle 14 at a time before and after the collection time T1. Specifically, the range of the vehicle in which the defective part 10b may be mounted can be limited to a range XA composed of ranges B1 and B2 (hereinafter also referred to as recall range XA). Hereinafter, the ranges B1 and B2 will be described in order.

  First, since the signboard 12b is not collected at the collection time T0 and the signboard 12b is collected at the collection time T1, at least a range from the vehicle 14a next to the collection time T0 to the vehicle 14b immediately before the collection time T1. It can be seen that the first defective part 10b of the mailing box 11b was used in any of the vehicles of B1. In addition, other defective parts 10b of the mailing box 11b may be mounted on the vehicle in the range B1. Note that the two signboards 12a and 12b are collected at the collection time T1, but which signboard was placed first at the collection position, in other words, which of the mailings 11a and 11b It is unclear whether the component 10 housed in was used first. Therefore, as described above, the defective part 10b may be mounted on all the vehicles 14 in the range B1.

  Next, the range B2 is a range that is set in consideration of the possibility that the defective part 10b of the passing box 11b remains unused at the collection time T1. That is, the signboard 12b is placed at a collection position by an operator when the first defective part 10b accommodated in the box 11b is used, and then collected by another worker. Therefore, even if the signboard 12b is collected at the collection time T1, it is not known whether or not all defective parts 10b have already been used at that time, and a maximum of three (four pieces accommodated in the box 11b). There is a possibility that the defective part 10b (the number obtained by subtracting the first one from the left) still remains in the box 11b. Therefore, the defective part 10b may be mounted on the vehicle 14 after the collection time T1.

  Considering the presence of such a defective part 10b that may remain at the collection time T1, a range B2 in which the defective part 10b may be mounted is set. The range B2 can be set as an effective range as appropriate, but in the present embodiment, it is set to a range for three vehicles.

  As described above, the defective part 10b accommodated in the box 11b may be mounted on the vehicle 14 in the range XA including the ranges B1 and B2. In the recall range XA, there are nine vehicles 14 on which the component 10 is mounted. That is, since there are nine recalled vehicles 14 for four defective parts 10b housed in the box 11b, the vehicle recovery rate is 225%. The smaller the collection of extra vehicles, the better this recovery rate approaches 100%.

  By the way, the parts to be recalled are not limited to the parts that are directly incorporated in the assembly line 13 of the vehicle 14 like the above-described parts 10. In other words, there are parts that are incorporated into the vehicle 14 indirectly by being incorporated in the intermediate assembly in the intermediate assembly line, and this intermediate assembly is incorporated in the vehicle 14 in the assembly line 13. When the recall range is set for the components that are indirectly incorporated in this way, it is necessary to set a range B3 in consideration of the time difference caused by the intermediate assembly in addition to the above ranges B1 and B2. Hereinafter, the range B3 will be described. Since the ranges B1 and B2 can be set by the same method as that for the component 10, the description thereof is omitted here.

  For example, as illustrated in FIG. 4A, an intermediate assembly line (assembly line) 20 is provided separately from the assembly line 13 of the vehicle 14. In the intermediate assembly line 20, an intermediate assembly 21 that is a part mounted on the vehicle 14 is assembled. A component 22 is mounted on the intermediate assembly 21.

  In the assembly line 13, the vehicle 14 continuously flows in the direction of arrow A. Further, in the intermediate assembly line 20, the intermediate assembly 21 flows in the direction of arrow B, and the part 22 is incorporated into the intermediate assembly 21 at the work position C.

  In the assembly line 13, the component 10 housed in the box 11 a is incorporated in the vehicle 14. Further, in the intermediate assembly line 20, the part 22 accommodated in the box (part box) 23 a is incorporated in the intermediate assembly 21.

  Here, the first part 22A of the box 23a is incorporated into the intermediate assembly 21A in the same time zone as the time when the first part 10A of the box 11a is incorporated into the vehicle 14A. It is assumed that the sign 12a attached to the box 11a and the sign (recording material) 24a attached to the box 23a are collected at the same collection time T1.

  The vehicle 14 in which the part 10 </ b> A is incorporated flows to a process further downstream of the assembly line 13. Further, the intermediate assembly 21 </ b> A in which the part 22 </ b> A is incorporated flows through the intermediate assembly line 20.

  Then, as shown in FIG. 4B, when the assembly of the intermediate assembly 21A is completed, the intermediate assembly 21A is transported to the assembly line 13, and the vehicle 14F behind the vehicle 14A (upstream in the direction of arrow A). Mounted on.

  In this way, the component 10A and the component 22A are incorporated in each line at the same time zone, and the signboards 12a and 24a are collected at the same time T1. However, since the assembly line 13 continues to flow during the assembly of the intermediate assembly 21A and during the transportation of the intermediate assembly 21A to the assembly line 13, the vehicle in which the intermediate assembly 21A is incorporated is the part 10A. The vehicle 14F is behind the vehicle 14A incorporating the. As described above, a part that is directly incorporated in the assembly line 13 and a part that is incorporated in another line such as an intermediate assembly line and indirectly incorporated in the assembly line 13 may be parts that are incorporated in the same time zone. An opening occurs in the time zone in which the vehicle 14 is mounted. In the above example, the former is mounted on the vehicle 14A, and the latter is mounted on the vehicle 14F. In other words, even if a part is collected at the same collection time T1, considering that it is a part used in the intermediate assembly line 20, there is a possibility that the part 22 is mounted further to the rear by the amount described above. There is.

  The range B3 is a portion considering use in the intermediate assembly line as described above. In the present embodiment, the range B3 is set for five vehicles in consideration of the work time in the intermediate assembly line 20, the transport time of the intermediate assembly 21 to the assembly line 13, and the like. However, the present invention is not limited to this, and a necessary number can be set as appropriate.

  Here, as shown in FIG. 5, among the parts 22 incorporated in the intermediate assembly 21, the part 22b accommodated in the box 23b is defective, and the sign 24b attached to the box 23b is displayed at the collection time T1. It shall be collected. In this case, the recall range XB of the defective part 22b is the range B1 to B3. The ranges B1 and B2 are ranges set in the same manner as in the case of the component 10 described above.

  In this case, there are twelve vehicles 14 on which the parts 22 (intermediate assemblies 21) are mounted in the recall range XB. That is, since the number of vehicles 14 to be recalled is 12 for the four defective parts 22b accommodated in the box 23b, the vehicle recovery rate is 300%.

  Further, when the time difference occurring in the intermediate assembly line 20 is known in advance, the recall range XB can be limited by this amount. For example, let us consider a case where there is at least two vehicles for the time difference caused by the intermediate assembly line 20. In this case, first, the defective part 22b corresponding to the signboard 24b collected at the collection time T1 is used for the leading vehicle 14A in the range B1 even when it is used earliest. However, as described above, the time difference of at least two units is caused by the assembly by the intermediate assembly line 20, so that the defective part 22b is included in the two vehicles, the leading vehicle 14A and the rear vehicle 14B. There is a possibility of being mounted on vehicles after the vehicle 14C without being mounted. Thus, if the minimum time difference caused by the intermediate assembly line 20 is known, the recall range on the head side (range B1 side) can be partially limited.

  By the way, the above-mentioned recovery rate decreases as the range of defective parts increases, and approaches 100%. For example, let us consider a case where all the parts in the box collected by the collection times T1 to T100 are defective. Then, as shown in FIG. 6, with respect to the respective collection times T1 to T100, the recall ranges are set as ranges X1 to X100, and the entire recall range is set as range X.

  In this case, with respect to the recall range X, extra recall ranges Y and Y occur on both sides thereof, and the range of the vehicle in which defective parts are actually mounted is the range Xa. In other words, if there are defective parts continuously over multiple collection times, it is not clear whether any defective parts are mounted on the vehicle at the collection time on the center side. Is only the time zone on both sides. For this reason, as the recall range becomes larger, the ratio of the time zone on the center side becomes relatively larger, and conversely, the ratio of the extra recall range Y becomes relatively smaller. As a result, the recovery rate approaches 100%.

  As described above, in the traceability management method of the present embodiment, the range of a vehicle on which a specific part is mounted is limited as described above by recording and managing the part information on a signboard attached to the pass. be able to. Thereby, for example, even when a recall occurs in the market, the recall range can be reduced.

  Further, by recording and managing the component information on the signboard, the cost of the component does not increase as in the method of processing the component itself and recording the component information. Since the signboard attached to the box can be repeatedly used in the manufacturing process of the vehicle, the cost increase due to the provision of the signboard can be reduced. In particular, in the present embodiment, since a signboard that has been conventionally used for parts inventory management is used as a recording material, the traceability of the components can be improved without causing an increase in cost due to the provision of the recording material.

  In addition, by managing the traceability of parts on a mailing unit basis, for example, the number of times the signboard is placed at the collection position can be reduced as much as possible, compared to the case where each part is managed. Can reduce the work burden. In particular, in the present embodiment, the work of placing the signboard at the collection position and the work of collecting the signboard are operations conventionally performed for parts management, so that the number of work steps that are increased for traceability management is minimized. Can be stopped.

  By the way, when managing the traceability of parts in a mailing unit, it is impossible to distinguish each part accommodated in the same mailing, but this does not cause a big problem. In other words, parts housed in the same box are often produced under the same production conditions and environmental conditions. For this reason, for example, as in this embodiment, when it is necessary to increase traceability for the purpose of limiting the recall range, when one of the parts accommodated in a certain box is defective, the other parts There is a high possibility of being a defective product, and there is little need to distinguish these parts. In this way, by managing the traceability of parts in units of boxes, it is possible to realize a traceability management method that achieves both convenience and practicality that can reduce work effort as much as possible.

  The embodiment of the present invention has been described above, but the present invention is not limited to the above-described embodiment, and it is needless to say that various modifications can be made without departing from the gist of the present invention.

  In the above description, the worker performs the work of incorporating the component 10 into the vehicle 14 and the work of collecting the signboard at the collection position. However, these works may be automated by a machine.

  In the above embodiment, for the purpose of managing the traceability of the parts mounted on the vehicle, the case where a part of the parts is found to be defective and a recall occurs is illustrated. However, the purpose of managing the traceability of parts is not limited to this. For example, when there is a difference in performance within the range of normal quality in individual vehicles, it can also be used for the purpose of investigating the cause.

  In the above embodiment, as shown in FIG. 1, the case where the component 10 is produced at the component factory K1 and directly conveyed to the vehicle assembly factory K2 is shown. However, the present invention is not limited to this. For example, as shown in FIG. 7, a warehouse K <b> 3 that temporarily stores the part 10 may be provided between the part factory K <b> 1 and the assembly factory K <b> 2 of the part 10. The parts 10 produced at the parts factory K1 are accommodated in the production side box 15 of the parts factory K1 and transported to the warehouse K3. Then, it is subdivided in the warehouse K3 and accommodated in the respective boxes (part boxes) 11a to 11d, and signs (recording materials) 12a to 12d are respectively attached to the boxes 11a to 11d. Each of the boxes 11a to 11d is transported to the assembly plant K2 and used for the vehicle assembly line. A production side signboard 16 is attached to the production side mailing box 15, and information such as the production date and time of the part 10 is recorded on the production side signboard 16. When subdividing the parts 10 into the boxes 11a to 11d in the warehouse K3, it is necessary to associate the production side signboard 16 with the signboards 12a to 12d. Thereby, finally, information such as the production date and time of the part 10 can be associated with the vehicle on which the part 10 is mounted, and the traceability of the part 10 can be improved. Further, a factory for assembling an intermediate assembly on which the part 10 is mounted may be interposed between the parts factory K1 and the vehicle assembly factory K2.

10 parts 11 mailing (parts box)
12 Signboard (recording material)
13 Assembly line 14 Vehicle (product)
20 Intermediate assembly line (assembly line)
21 Intermediate assembly 22 Parts X, XA, XB Recall range

Claims (1)

In the traceability management method for parts mounted on products,
A step of providing a component box having a recording material in which a plurality of the components are accommodated and recording a state of the accommodated components in an assembly line for incorporating the components;
In the manufacturing process of the product, when the component is assembled, the step of arranging the recording material of the component box containing the component at a collection position;
Collecting the recording material arranged at the collection position at a specific collection time;
The step of limiting the range of products in which the parts contained in the predetermined part box may be mounted based on the part information of the recording material of the predetermined part box and the recovery time of the recording material And traceability management methods.

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