JP2019167184A - Storage space management method - Google Patents

Abstract

To improve the storage capacity of a storage space for coils while maintaining prevention against wrong shipment of coils and convenience in shipping work.SOLUTION: In work lot units imparted to coils at the same manufacture timing among coils of the same shipment lot, a design storage space code present only in a system is set in replacement with a position (actual address) of an actual storage space in response to a carrying-out/in work indication from a storage space, and a virtual section where coils are stored in the same work lot units is set. The design storage space code is specified and carrying-in work for coils to the storage space is indicated. Problems characteristic of coils of a wire material or a rod wire such that wrong shipment is apt to occur since many lightweight coils are carried and it is complicated to make a check for preventing the wrong shipment are solved, and then the section can be set in response to change in the number of coils of lots, thereby effectively making good use of the storage capacity of the storage space.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a placement management method in a placement management system for wire coils or bar coils.

  Part of the steel bar product and wire product are manufactured through a process such as rolling and stored in a coiled package. For example, in rolling processing, multiple work lots that consolidate coils with similar rolling sizes (dimensions) and the same shipping destination and shipping date are processed together at the same rolling chance, reducing the frequency of changing the rolling size. The rolling work is done reasonably.

  There are various work lots of coils of wire rods or bar steels manufactured in this way. For example, work lots of wire coils exist from a large one of about 250 coils to a small one of coils, for example. In addition, the shipping dates (periods from the completion of manufacturing to shipping) of each work lot manufactured at the same rolling chance are various.

  Here, the wire coil is about 0.5 to 2 tons per coil and is lighter than the thin plate coil, and a plurality of (for example, about 2 to 8 coils) coils are collectively transported in the coil loading / unloading operation. It is generally done. For this reason, there is a high possibility that erroneous shipment such as not shipping a coil to be shipped occurs compared to a product that is transported in units of one coil such as a thin coil. Therefore, conventionally, as a method for preventing erroneous shipment, a plurality of minimum unit locations divided by a certain area or number of units are set in the coil location, and one location (each minimum unit location) is set. Only the coil of a specific work lot is stored. However, since the sizes of work lots are various, empty places are generated in the place divided by a certain area or number unit, and the place cannot be effectively used.

  For such a problem, for example, Patent Document 1 discloses a method of disposing a plurality of coils in a width direction or a radial direction in the longitudinal direction of the coil yard on a coil yard for a thin plate coil. ing. In such a method, the coil yard is a coil yard in which the coil can be arranged at an arbitrary position, the coil yard is partitioned in the front-rear direction at a predetermined unit interval, and the occupied dimension in the width direction or the radial direction is the predetermined unit interval. Multiple coils are sequentially arranged from the front of the coil yard, and coils whose width or radial occupation dimension is different from the predetermined multiple of the unit interval are rearward of the coil yard. Arrange sequentially. Thereby, the storage position in the coil place is set according to the coil size, so that the storage capacity of the coil place can be fully utilized.

  Further, in Patent Document 2, in the determination of the cargo handling work of the target warehouse, the current storage is based on the inventory information indicating at least the storage position of the product currently stored in the target warehouse and the shipped product information indicating the shipping conditions. The products in the target warehouse are divided into groups of products with similar shipment conditions, and the area where the products in the group are collected and arranged is determined for each group based on the constraint conditions and inventory information of the target warehouse. Based on the transport information and shipped product information, it is determined whether there is a product entry / exit operation that should be performed at the target warehouse. If there is an entry / exit operation, the execution of the entry / exit operation is determined and there is no entry / exit operation. In this case, it is decided to execute the replacement work to collect and arrange each product in the group in the same area, and instruct the control system of the loading / unloading equipment of the target warehouse about the loading / unloading work or replacement work that has been determined to be executed. Instruction information It is disclosed that the output. In the method of Patent Document 2, products having similar shipping conditions are grouped, and an area to be stored for each group is determined to improve shipping work efficiency.

JP 2000-155931 A Japanese Patent Laid-Open No. 2006-222455

  However, although the method of Patent Document 1 can use the storage capacity of the storage site, coils of different work lots are mixed in the storage site of the same section. For this reason, there have been problems such as shipping to an unscheduled shipping destination, not shipping a coil to be shipped, etc., and complicated checks to prevent the coil from being shipped incorrectly. .

  In the method described in Patent Document 2, although the shipping work efficiency is improved, the storage position is designated and managed in units of one coil. For this reason, although there is a low frequency, there is an unmatch between the data and the actual storage position, such as storing the coil in a storage position different from the instructed storage position, or removing the coil from a storage position different from the instructed storage position. May occur. In order to completely prevent such unmatching, the storage position and the product check at the time of unloading become complicated, which may cause erroneous shipment.

  Therefore, the present invention has been made in view of the above problems, and an object of the present invention is to carry out a check for the purpose of preventing erroneous shipment of wire coils or steel bar coils, and checking for preventing erroneous shipment. It is an object of the present invention to provide a new and improved place management method in a place management system capable of maintaining the convenience of work and improving the storage capacity of a coil place.

In order to solve the above-described problem, according to one aspect of the present invention, there is provided a placement management method by a placement management system for a placement location in which a coil of a wire rod or a steel bar is stored. Can be arranged in a row with the through-directions aligned, and a plurality of rows can be arranged in the horizontal and vertical directions adjacent to each other in the coil radial direction. The actual position of the storage location shown is the actual address, and the coils are given a shipping lot number with at least a plurality of coils having the same shipping date and shipping destination as the same shipping lot, and within the same shipping lot. A work lot number is assigned to a plurality of coils having the same manufacturing timing as the same work lot, and a carry-in coil for a carry-in coil that is carried into the storage site is provided. The design site code setting step for setting the design site code representing the carry-in position of the carry-in coil, and the design site code for the carry-in coil, the shipping lot, and the work lot for the actual address Based on the loading coil registration step to be registered in the parking table and the design coil code of the loading coil specified by the work instructor, the actual address corresponding to the design parking code and the design parking code are given from the parking table A loading instruction step of obtaining a coil number of the coil that has been received and notifying an operator of the actual address. In the design location code setting step, the number of coils in the working lot of the loading coil for the loading coil of the same work lot Based on n and the number C of coils that can be stored in one real address, the carry-in coil of one work lot is stored. Calculates the storage columns Cp necessary, based on the number N of yard and storage columns Cp, calculates the number of columns P ₀ of the first stage required to store the storage columns Cp, coils in yard Among the sections in which the number of rows in the first stage is at least the number of rows P ₀ required to store the number of storage columns Cp is determined as the loading section of the loading coil. A placement management method is provided in which the coil number of the carry-in coil and one design place code are set at the real address corresponding to the carry-in section.

  In the storage management method, for each design storage code set in the design storage code setting step, whether or not the maximum number of coils that can be stored in the section to which the design storage code is assigned is equal to or greater than the number of carry-in coils. It may further include a design place code judging step for judging whether or not.

  In addition, an RFID tag in which a real address code capable of specifying the real address is recorded is installed in the storage site, and an actual device recorded in the RFID tag is provided in a transfer device that transports and unloads coils from the storage site. An RFID reader that reads the address code may be provided. At this time, the storage management method. Real address code that reads the real address code recorded on the RFID corresponding to the carry-in position of the carry-in coil by the RFID reader of the carry-in device when the worker carries the carry-in coil to the place by the carry device after receiving the carry-in instruction step In the reading step and the storage table, the design site code corresponding to the actual address specified from the actual address code is compared with the design site code specified by the work instructor in the import instruction step, and the design site code is compared. May further include a loading position check step of notifying the worker of an instruction to redo the loading work of the loading coil.

  At this time, the storage management method registers the coil storage position in the storage table by associating the coil number of the input coil with the actual address where the coil is input when the design storage codes compared in the input position check step match. A coil storage location registration step may be further included.

  In addition, the placement management method obtains at least the actual address corresponding to the shipping lot from the placement table based on the shipping lot designated by the work instructor when unloading the coil to be unloaded from the placement, It may further include a carry-out instruction step for notifying to.

  At this time, after the coil is carried out by the carry-out instruction step, at least the coil number associated with the actual address of the place where the coil was carried out is deleted from the place table.

  As described above, according to the present invention, it is possible to maintain the convenience of carrying out work for preventing erroneous shipment of wire coils or steel bar coils, and carrying out work for facilitating checking for the purpose of preventing erroneous shipment, and for the installation of coils. Storage capacity can be improved.

It is a schematic perspective view which shows a part of storage place which concerns on one Embodiment of this invention. It is explanatory drawing which shows the state which looked at the place shown in FIG. 1 from the front and the substantially upper surface. It is explanatory drawing which shows the conveying apparatus which conveys a coil. It is explanatory drawing explaining operation | movement of the conveying apparatus when carrying out a coil from a placement. It is a block diagram which shows the structure of the storage management system which concerns on the same embodiment. It is explanatory drawing which shows one structural example of a shipping table. It is explanatory drawing which shows the example of 1 structure of a placement table. It is explanatory drawing which shows the storage state of the coil of the place represented by the place table of FIG. It is a flowchart which shows the placement management method by the placement management system which concerns on the embodiment. It is explanatory drawing explaining a carrying-in coil registration process. It is explanatory drawing explaining conversion to the real address of the design place code at the time of carrying-in processing. It is explanatory drawing explaining a storage location registration process. It is explanatory drawing which shows the placement conditions in the verification 1. FIG. It is explanatory drawing explaining the placement management by the conventional method of the comparative example 1. FIG. It is explanatory drawing explaining the placement management in the mixed storage method of the comparative example 2. FIG. It is explanatory drawing explaining the storage management by the method of this invention of Example 1. FIG. It is a graph which shows the verification result of verification 2.

  Exemplary embodiments of the present invention will be described below in detail with reference to the accompanying drawings. In addition, in this specification and drawing, about the component which has the substantially same function structure, duplication description is abbreviate | omitted by attaching | subjecting the same code | symbol.

<1. Overview>
A placement management system according to an embodiment of the present invention is a system for managing a placement in which a wire rod or a steel bar coil is stored, and manages a storage position of a coil stored in the placement. An outline of a place managed by the place management system according to the present embodiment is shown in FIGS. FIG. 1 is a schematic perspective view showing a part of a place according to the present embodiment. FIG. 2 is an explanatory diagram illustrating a state where the parking space illustrated in FIG. 1 is viewed from the front and substantially from the top.

  As shown in FIGS. 1 and 2, the placement of the coil 10 managed by the placement management system according to the present embodiment can be arranged in a row with a plurality of coils 10 aligned in the depth direction with the penetration direction of the coil hole 10a. In addition, a plurality can be arranged in the horizontal and vertical directions adjacent to each other in the coil radial direction. One or more coils 10 arranged in the depth direction are also referred to as a coil row. In the yard, the actual position of the coil array is represented by a position in the horizontal direction as a row and a position in the vertical direction as a step. Hereinafter, the actual position of the coil array represented by the array and the stage is referred to as “actual address”.

  A support member 5 that extends in the depth direction and supports the coil 10 is disposed in the horizontal direction on the placement surface of the placement site. A pair of support members 5 and 5 support one coil row in the first stage. The coil arrays arranged in the second and subsequent stages are placed between two adjacent coil arrays placed in the stage immediately below. That is, as shown in FIGS. 1 and 2, the coils 10 are so-called stacked and stored in a storage place. The number of stages at which the coils 10 can be stacked in the storage site is set in advance depending on the type of coil, the height at which the transfer device can be stacked, the height restriction of the warehouse facility, and the like, and the top stage is the Nth stage. In addition, an RFID tag 20 in which a real address code capable of specifying a real address row is recorded corresponding to the position in the horizontal direction of the coil row is installed in the place. The real address code may be the real address column itself.

  For example, the coil 10 is carried into and out of the place by a transfer device 30 as shown in FIG. The conveying device 30 is a device that suspends and conveys the coil 10 on a fork portion 32 that can move up and down. For example, at the time of carrying out the coil, the transport device 30 adjusts the height position of the fork portion 32 to the height position of the carry-out coil, and then moves forward along the depth direction of the storage place. 32 is passed through the coil hole 10 a of the coil 10. Then, it moves rearward and conveys the coil 10 suspended on the fork portion 32. One fork unit 32 can transfer one or a plurality of coils 10 from one coil row. For example, in the transfer device 30 in FIG. 4, two fork units 32 are installed in the horizontal direction. The coils 10 of the two coil arrays can be simultaneously transported by one transport operation. In the present embodiment, the number of fork portions 32 provided in the transport device 30 is not particularly limited, and only one or three or more fork portions 32 may be provided.

  The transport device 30 is provided with an RFID reader 34 and a height position sensor 35 as devices for acquiring the actual address of the place. The RFID reader 34 reads the real address code recorded on the RFID tag 20 installed in the place. Further, the height position sensor 35 detects the height of the fork portion 32. From the height of the fork portion 32 detected by the height position sensor 35, the number of stages to carry the coil 10 in and out can be grasped. Thereby, for example, it is possible to grasp at what stage the coil is going to be carried in or what stage the coil is going to be carried out.

  In this way, the actual address of the place can be specified by combining the actual address code read by the RFID reader 34 and the detection result by the height position sensor 35. Note that if the number of coils placed in the yard is two or less, the positions of the first and second coil rows in the horizontal direction are misaligned. It can be specified whether the position of the direction is the first stage or the second stage. In this case, the height position sensor 35 is not always necessary.

  In the placement management system according to the present embodiment, at least one coil having the same shipping date, shipping destination, and manufacturing timing is grouped as the same work lot with respect to the coils carried in / out of such a placement. The instruction to carry the coil in and out of the storage site is given in units of work lots, not a unique coil number assigned to identify each coil. For this reason, the coils of the same work lot are managed as an assembly of coil arrays, and are collected and stored in one place. At this time, in the placement management system according to the present embodiment, a virtual section composed of the minimum number of coil rows is set for the placement according to the size of the work lot, and the storage position of the coil is managed. The virtual section of the place set on this computer is represented as a design place code. Only one coil of the same work lot is stored in one virtual section. Thus, by designating the design place code, it is possible to instruct loading / unloading of coils in the same work lot.

  In this way, by managing the coil storage tank position with the design site code, the maximum number of coils that can be stored in one design site code can be changed according to the size of the work lot, so the storage of the site is possible. Ability can be increased. In addition, by designating coil loading / unloading in units of design place codes, the number of instructions is reduced compared to when coil loading / unloading is designated by the coil number assigned to each coil, thus reducing erroneous instructions. can do. Therefore, erroneous shipment of the coil can be prevented. Furthermore, coils of the same work lot to which the same design place code is assigned are piled up in the place as one group. At this time, since the design place code is set so that coils of different design place codes are not mixed, the coil placed in the place is visually recognized to easily recognize the coil of the same work lot. Can do. Therefore, if one group of coils is no longer in the storage area, it can be easily confirmed visually that all the coils instructed to be carried out have been carried out.

<2. Storage management system>
Based on FIG. 5, the structure of the placement management system 1 is demonstrated. FIG. 5 is a block diagram illustrating a configuration of the storage location management system 1 according to the present embodiment. FIG. 5 shows only functional units that function when executing processing for managing the storage position of the coil.

  As shown in FIG. 5, the placement management system 1 according to the present embodiment includes a transfer device 30 that carries a coil into and out of the placement, and a placement management device 100 that manages a storage position of the coil stored in the placement. Consists of.

[2-1. Transport device]
As shown in FIG. 3, the transfer device 30 is a device that transfers the coil. As shown in FIG. 5, the transport device 30 has functions other than holding and transporting the coil to be transported by the fork unit 32, as shown in FIG. 5, a notification unit 31, an actual address acquisition unit 33, an actual address calculation unit 37, and a loading position. And a check unit 39.

  The notification unit 31 notifies the worker of notification information. The notification unit 31 is, for example, a display that displays information, and may further include a speaker that outputs sound. The notification information from the placement management apparatus 100 includes, for example, the actual address of the coil loading position or the unloading position. In addition, notification information from a loading position check unit 39, which will be described later, includes an instruction to redo a loading operation to notify an operator when a coil is not correctly loaded in a designated place. In response to the notification information from the notification unit 31, the worker carries the coil.

  The actual address acquisition unit 33 is a functional unit for acquiring information for specifying the actual address of the place, and includes, for example, an RFID reader 34 and a height position sensor 35 as shown in FIG. The real address acquisition unit 33 outputs the real address code read from the RFID tag 20 by the RFID reader 34 and the height of the fork unit 32 detected by the height position sensor 35 to the real address calculation unit 37 as acquisition information.

  The actual address calculation unit 37 calculates the actual address of the coil based on the acquisition information acquired by the actual address acquisition unit 33. The real address calculation unit 37 calculates a real address representing the actual position of the place by combining the real address code acquired by the RFID reader 34 and the acquired information of the height position sensor 35 or from only the real address code. The actual address calculation unit 37 outputs the calculated actual address to the loading position check unit 39 when the coil is loaded.

  The carry-in position check unit 39 confirms whether or not the coil is correctly carried into the designated place when the coil is carried in. The carry-in position check unit 39 outputs an instruction to redo the carry-in work to the notification unit 31 when the coil is not correctly carried into the designated place. As a result, the operator is notified of an instruction to redo the carry-in work via the notification unit 31. When the coil is correctly carried into the designated place, the carry-in position check unit 39 outputs an instruction to record the coil number of the coil carried into the place to the place management apparatus 100.

[2-2. Place management device]
The placement management device 100 includes an information processing unit 110 that determines a coil storage position and instructs the transfer device 30 to carry in and out the coil, and a data storage unit 120 that stores data related to the placement of the coil. The information processing unit 110 includes a shipping lot determination unit 111, a work lot determination unit 112, a design place code setting unit 113, a transfer work instruction unit 114, an update processing unit 115, and an input unit 116. The data storage unit 120 includes a shipping table 121 and a storage table 123.

(Information Processing Department)
The shipping lot determination unit 111 determines a shipping lot for the coil. Coils having at least the same shipping date and shipping destination are managed as the same shipping lot. The shipping lot determination unit 111 acquires at least the shipping date and the shipping destination of each coil from an order management server (not shown) that manages the order information, and the same shipment of the coils having the same shipping date and shipping destination. As a lot, the same shipment lot number is given to these coils. The shipping lot determination unit 111 records the shipping lot number assigned to each coil in the shipping table 121 in association with at least the coil number.

  The work lot determination unit 112 determines a work lot for the coil. Of the coils in the same shipment lot, coils having the same manufacturing timing are managed as the same work lot. In the production of products in a factory, it is customary to produce products of the same material and the same rolling size together, and many coils of the same material and the same rolling size are included in the same shipping lot. From this, it is considered that the coils that are the same shipment lot can be classified and grouped into one or a plurality of work lots. Coils of the same work lot are manufactured together at the same time, that is, at the same manufacturing timing. The work lot determination unit 112 assigns the same work lot number to the coils having the same manufacturing timing as the same work lot among the coils of the same shipment lot. The work lot determination unit 112 records the work lot number assigned to each coil in the shipping table 121 in association with at least the coil number.

  By the shipping lot determination unit 111 and the work lot determination unit 112, information in which at least a shipping lot number and a work lot number are associated with each coil number of each coil is recorded in the shipping table 121.

  The design place code setting unit 113 calculates a carry-in position of the place where the carry-in coil is carried in for the carry-in coil which is a coil carried into the place, and sets a design place code representing the carry-in position of the carry-in coil. Details of the design site code setting process by the design site code setting unit 113 will be described later. Further, the design site code setting unit 113 determines whether or not the maximum number of coils that can be stored in the section of the site to which the design site code is assigned is equal to or greater than the number of carry-in coils for the set design site code. Determine. The design place code setting unit 113 recalculates the section of the place until the condition is satisfied. When the placement section is calculated until the condition is satisfied, the design place code setting unit 113 records the associated design place code, work lot number, and shipping lot number in association with the actual address in the place table 123. .

  In response to the input of the transport instruction information from the work instructor to the input unit 116, the transport work instruction unit 114 instructs the transport device 30 on the transport destination of the coil to be transported. When the coil is loaded, the transfer work instruction unit 114, when the design place code of the coil to be loaded designated by the work instructor is input to the input unit 116, the design place code from the place table based on the design place code. The real address and the coil number corresponding to are acquired, and the real address is notified to the operator via the notification unit 31 of the transport device 30. In addition, when the coil is unloaded, the transfer work instruction unit 114, when the shipment lot of the coil to be unloaded designated by the work instructor is input to the input unit 116, is changed from the placement table to the shipment lot based on the shipment lot. The corresponding real address is acquired, and the real address is notified to the operator via the notification unit 31 of the transport device 30.

  The update processing unit 115 updates the placement table 123 according to the loading / unloading of the coil into / from the placement. When the coil is loaded, the update processing unit 115 receives an instruction to record the coil number of the coil loaded into the placement from the transfer device 30 when the coil is correctly loaded into the designated placement. Based on the instruction, the update processing unit 115 records the coil number of the loaded coil at a position corresponding to the actual address of the placement table. When the coil is unloaded, the update processing unit 115 deletes the coil number of the unloaded coil recorded in the placement table when an instruction for unloading the coil from the transfer work instruction unit 114 to the transfer device 30 is output. Is done.

  Information input by the work instructor using an input device (not shown) is input to the input unit 116. The design place code is input from the work instructor to the input unit 116 when the coil is carried in, and the shipping lot is inputted from the work instructor when the coil is carried out. Note that the input device used by the work instructor may be, for example, a keyboard or a touch panel.

(Data storage)
The shipping table 121 stores information relating the coil number of each coil and at least the shipping lot number and the work lot number. An example of the configuration of the shipping table 121 is shown in FIG. In the shipping table 121 shown in FIG. 6, in addition to the coil number, the shipping lot number, and the work lot number, the work lot weight, the shipping date, and the shipping destination ID for specifying the shipping destination are recorded.

  In the storage table 123, the coil number of the coil stored in the actual address, the work lot number, the shipping lot number, and the design storage code are recorded for each actual address of the storage site. One structural example of the placement table 123 is shown in FIG. In the placement table 123, a value set by the design placement code setting unit 113 is set in the design placement code. As the coil number, a value corresponding to the coil carried into the real address is set, and when the coil is carried out, the set value is deleted. That is, the coil is not stored in the real address where the coil number is not set like the coil number cell of the real address (column 02: stage 3) in FIG. As the work lot number and the shipping lot number, values corresponding to the coils stored in the actual addresses are set from the shipping table 121.

  For example, the placement table 123 of FIG. 7 shows the storage state of the coils of the placement shown in FIG. FIG. 8 shows a group in which coils 10 having coil numbers A0 to A4 are stacked in two stages and a group in which coils 10 having coil numbers A5 to A7 are stacked in two stages. The actual address of each coil is represented by a column number (01, 01, 02, 02, 03,...) And the number of stages (first stage, second stage, third stage,...). The same shipping lot number (AA01) is assigned to the coil numbers A0 to A7, and the same work lot number (a001) is assigned to the coil numbers A0 to A4 according to the production timing. The same work lot number (a002) is assigned to A7. And the same design place code is given with respect to the coil of the same work lot. That is, the same design place code (X1) is assigned to the coil numbers A0 to A4, and the same design place code (X2) is assigned to the coil numbers A5 to A7.

  With such a placement table 123, the coil 10 with the coil number A0 is stored at the actual address (column 01: stage 1), and the shipping lot number, work lot number, and design place code of the coil can be specified. . In addition, since no coil is stored in the real address (column 02: stage 3), no value is set in the coil number cell of the record.

  The functional configuration of the placement management system 1 has been described above. 5, the real address calculation unit 37 and the carry-in position check unit 39 that process the information acquired by the real address acquisition unit 33 of the transport device 30 are provided in the transport device 30. However, the present invention is not limited to such an example. For example, the actual address calculation unit 37 and the carry-in position check unit 39 may be provided in the storage location management apparatus 100. In this case, the information acquired by the real address acquisition unit 33 of the transport device 30 is transmitted to the placement management device 100, and the placement management device 100 calculates the actual address of the coil. Further, the placement management apparatus 100 also confirms the coil loading position.

<3. Storage management method>
Based on FIG. 9, the placement management method by the placement management system 1 will be described. FIG. 9 is a flowchart showing a placement management method by the placement management system 1 according to the present embodiment.

(Lot determination processing: S100, S102)
In the placement management method by the placement management system 1 according to the present embodiment, as shown in FIG. 9, first, the shipment lot determination unit 111 determines the shipment lot of the coil (S100). The shipping lot determination unit 111 sets at least coils having the same shipping date and shipping destination as the same shipping lot. The shipping lot determination unit 111 acquires at least the shipping date and shipping destination of each coil from an order management server (not shown) that manages order information, and the acquired shipping date and shipping destination are the same for the same coil. The shipping lot number is assigned. The shipping lot determination unit 111 records the shipping lot number assigned to each coil in the shipping table 121 in association with at least the coil number.

  Next, the work lot determination unit 112 determines a coil work lot (S102). The work lot determination unit 112 sets coils having the same manufacturing timing as coils in the same shipment lot as the same work lot. The work lot determination unit 112 assigns the same work lot number to the coils having the same manufacturing timing as the same work lot among the coils of the same shipment lot. The work lot determination unit 112 records the work lot number assigned to each coil in the shipping table 121 in association with at least the coil number.

  By the processing in steps S100 and S102, for example, a shipping table 121 as shown in FIG. 6 is created.

(Design place code setting process: S104, S106)
When the shipping table 121 is created, the design placement code setting unit 113 calculates the loading position of the loading location where the loading coil is loaded for the loading coil to be loaded into the placement location, and the design placement code representing the loading position of the loading coil is obtained. It is set (S104). The design site code setting unit 113 sets the design site code by performing the following process for the carry-in coil to which the same work lot number is assigned in step S102.

  First, the design site code setting unit 113 stores the carry-in coil of one work lot based on the number n of coils provided with the work lot number in the carry-in coil and the number C of coils that can be stored in one real address. The number Cp of storage columns necessary for this is calculated. Specifically, the storage column number Cp is calculated by the following formula (1). In other words, the number of coils C that can be stored in one real address is the number of coils that can be arranged in the depth direction of the yard. The calculated value according to equation (1) is rounded up to an integer.

  Cp = n / C (1)

Next, the design site code setting unit 113 calculates the first row number P ₀ necessary to store the storage column number Cp based on the number N of storage locations and the storage column number Cp. The first row number P ₀ required to store the storage column number Cp is the following equation (2-1), equation (2-2) or equation (2-3) depending on the value of the storage column number Cp. ). Note that N is the maximum number of stages that can be stacked in the storage area. The calculated values according to Equation (2-1), Equation (2-2), and Equation (2-3) are rounded up to an integer.

When 0 <Cp ≦ 2, Cp = P ₀ (2-1)
When 2 <Cp ≦ 3, Cp = P ₀ + P ₀ −1 (2-2)
When Cp> 3, Cp = Σ (P ₀ -k) (2-3)
(K = 0 to N-1)

And the design place code setting part 113 is a section where the number of first-stage columns is at least the number of first-stage columns P ₀ necessary for storing the number of stored columns Cp among the sections in which no coils are arranged in the place. Is determined as the loading section of the loading coil. And the design place code setting part 113 sets the coil number and design place code of a carrying-in coil to the real address corresponding to the decided carrying-in section with respect to the placing table 123. FIG. The section in which no coil is arranged in the place is a real address where the coil number of the place table 123 is not set. Therefore, the design Area code setting unit 113, the yard table 123 a real address of the coil number is not set, the real address of the vacant continuous only the column number P ₀ of the first stage, further columns of th stage When P ₀ is 2 or more, the same design place code is assigned to the 2nd to Nth real addresses stacked in the first row number P ₀ .

  When the design place code is assigned, the design place code setting unit 113 determines whether the carry-in coil can be stored in the section to which the same design place code is assigned (S116). Specifically, the design site code setting unit 113 confirms that the maximum number of coils that can be stored in the assigned design site code is equal to or greater than the number of coils to be loaded. In step S116, when the maximum number of coils that can be stored is smaller than the number of coils to be loaded, all the coils to be loaded cannot be stored in the section. At this time, the design site code setting unit 113 performs the process of step S104 again and resets the design site code. The design place code setting unit 113 recalculates the section of the place until the condition is satisfied.

(Carrying coil registration process: S108)
When the placement section is calculated until the condition of step S116 is satisfied, the design place code setting unit 113 records the associated design place code, work lot number, and shipping lot number in association with the actual address of the place table 123. (S108). As a result, the storage table 123 changes from the state where only the real address is registered as shown in the left side of FIG. 10 to the state where the design storage site code, the work lot number and the shipping lot number are set as shown in the right side of FIG. .

(Import process: S110)
The instruction to carry in the coil is given by the work instructor. When the coil is loaded, the transfer work instruction unit 114, when the design place code of the coil to be loaded designated by the work instructor is input to the input unit 116, based on the design place code, the design place code is read from the place table. The real address and the work lot number corresponding to are acquired, and the coil number to which the real address and the work lot number are assigned is notified to the worker via the notification unit 31 of the transfer device 30 (S110). The coil number to which the work lot number is assigned can be acquired by referring to the shipping table 121.

  For example, as shown in FIG. 11, when the design place code X1 is designated by the work instructor, the transfer work instruction unit 114 refers to the place table 123, and the actual address and work lot to which the design place code X1 is assigned. Get the number. The work lot number is converted into a coil number based on the shipping table 121. As a result, the operator is notified of the actual address corresponding to the design site code X1, not the design site code X1. The operator operates the transfer device 30 to carry the coil having the coil number notified from the notification unit 31 into the designated real address.

(Carry-in position check process: S112)
When the coil is carried in, the carrying device 30 acquires the actual carry-in position (that is, the actual address) where the coil is carried in. The acquisition of the real address from the storage location may be performed, for example, by reading the RFID tag 20 installed in the storage location by the RFID reader 34 of the transport device 30. Or you may acquire combining the reading result of the RFID tag 20 by the RFID reader 34 of the conveying apparatus 30, and the detection result of the height position sensor 35. FIG. Thereby, the carrying-in position which the carrying apparatus 30 actually carried in the coil can be grasped | ascertained.

  Then, the carry-in position check unit 39 refers to the placement table 123, compares the design place code at the carry-in position where the transfer device 30 actually carries the coil with the design place code designated by the work instructor, and Are determined to match (S112). In step S112, when the compared design place codes are different, the carry-in position check unit 39 notifies the worker of an instruction to redo the carry-in work of the carry-in coil. With this notification, the process of step S110 is performed again.

(Storage location registration process: S114)
On the other hand, when the design place codes compared in the carry-in position check in step S112 match, the carry-in position check unit 39 associates the coil number of the carry-in coil with the actual address where the coil was carried in, and stores the coil in the place table 123. The storage location is registered (S114). For example, when the coil with the coil number A0 is correctly loaded into the actual address of the design place code X1, as shown in FIG. 12, the coil number A0 is registered in the coil number cell at the actual address (column 01: stage 1). Is done. By the above process, the management of the place when the coil is carried in is performed.

(Export process: S116 to S120)
An instruction to carry out the coil stored in the storage area is also given by the work instructor. At the time of coil unloading, when the shipment lot of the coil to be unloaded designated by the work instructor is input to the input unit 116, the transfer work instruction unit 114 responds to the shipment lot from the placement table 123 based on the shipment lot. The actual address is acquired, and the worker is notified of the actual address via the notification unit 31 of the transport device 30 (S116). The operator operates the transfer device 30 and carries out the coil stored in the real address notified from the notification unit 31 (S118).

  When the coil is unloaded from the placement site, the update processing unit 115 deletes information related to the unloaded coil from the placement table 123 (S120). In step S120, at least the coil number may be deleted from the record of the real address where the coil is carried out. Information other than the actual address may be deleted from the storage table 123. When the placement table 123 is updated in step S120, the placement management method shown in FIG. 9 ends.

  The placement management method by the placement management system 1 according to the present embodiment has been described above. According to such a place management method, in the carry-in / out work instruction from the place, an instruction to specify a design place code set in units of work lots instead of an instruction to specify an actual address in units of coil numbers, or a design place code An instruction to carry out in units of shipment lots associated with is issued. Accordingly, it is possible to solve the problem peculiar to the coil of the wire rod or the rod wire that the erroneous shipment is likely to occur because a large number of light weight coils are conveyed, and the check for preventing the erroneous shipment is complicated.

  In addition, a virtual section for storing coils in lot units can be set using a design place code that exists only in the system instead of the actual place position (actual address). Thereby, it becomes possible to make it a division according to the fluctuation | variation of the number of coils of a lot, and the storage capacity of a storage place can be utilized effectively. Further, by storing only coils of the same work lot in one design place code, it is possible to easily check the completion of work lot unloading by visual confirmation.

[Verification 1: Coil storage capacity of the yard]
In verification 1, there are three types of locations: the conventional method shown in FIG. 14 (Comparative Example 1), the mixed storage method shown in FIG. 15 (Comparative Example 2), and the method of the present invention shown in FIG. 16 (Example 1). About the management method, the effect of the coil storage capacity of the yard was verified. In Verification 1, FIG. 13 and the following placement conditions were set in common with Comparative Examples 1 and 2 and Example 1.

(Common conditions (place))
Total number of coil arrays in the first stage: 400
Maximum number of stages: 3 stages Maximum number of coils per work lot: 300
Minimum number of coils per work lot: 1
Number of coils stored per coil row: 10

  Note that the number of coils per work lot was randomly set within 1 to 300 coils. Further, it is assumed that there are enough work lots to be stored in all the coil storage areas.

  In the conventional method of Comparative Example 1, as shown in FIG. 14, the section that can be stacked in 5 rows in the first row, 4 rows in the second row, and 3 rows in the third row is set to 80 compartments. did. Only one coil 10 of the same work lot was stored in one parking lot. That is, as shown in FIG. 14, the coil 10 of the work lot LOT1 is stored in the first place, and the coil 10 of the work lot LOT2 is stored in the second place.

  The mixed storage method of Comparative Example 2 is based on the method of Patent Document 2, and does not divide the storage place as in the prior art shown in FIG. 14, and as shown in FIG. Existed and piled up. However, only the coils 10 of a specific work lot are stored in the same row. That is, coils in different work lots are not stored in the same row.

  In the mixed storage method, when the coil of the work lot in the lower part is carried out, it is necessary to move the coil of the work lot in the upper part to another place once. For example, in order to carry out the coil of the work lot LOT3, a sorting operation for moving the third-stage coil of the work lot LOT4 to another place is necessary. Thus, as a place for temporarily moving the coil to another place, it is generally necessary to leave about 20% of the number of stored coils. Therefore, in this verification 1, it was assumed that 20% of the number of storage coils was left open.

  In the method of the present invention of Example 1, the virtual section for storing the coil was set using the design place code. Only one coil 10 of the same work lot was stored in one place. For example, as shown in FIG. 16, according to the number of coils of the work lots LOT1, LOT2, LOT3,..., 1 placement, 2 placement, 3 placement,. . Table 1 shows the result of verification 1.

  Regarding the number of storable lots and the number of storable coils, Example 1, which is the method of the present invention, is improved by a little less than 30% compared to the conventional method of Comparative Example 1, and results comparable to the mixed storage method of Comparative Example 2 Met. However, in the method of the present invention, the cause of erroneous shipment is suppressed by using the design place code as compared with the mixed storage method of Comparative Example 2. Therefore, in the premise that the storage area is constant, it can be said that by using the method of the present invention, it is possible to perform storage management with the storage capacity equivalent to that of the mixed storage method, while suppressing the cause of erroneous shipment.

[Verification 2: Comparison of the number of safety stock coils]
Considering the variation in the production capacity of the production line, it is necessary to stock a certain amount of coils (the number of safety stock coils) as insurance when the production capacity is less than planned. If the number of coils to be carried out per shipment (the number of coils loaded on a ship or truck) is constant, the storage capacity of the required storage space is the number of coils to be shipped and the number of safety stock coils per shipment. Determined by sum. Therefore, the required storage capacity can be reduced as the number of safety stock coils is reduced. In Verification 2, the number of safety stock coils was compared for the conventional method of Comparative Example 1 verified in Verification 1 above, the mixed storage method of Comparative Example 2, and the method of the present invention of Example 1.

In verification 2, the following conditions were set.
(1) It is assumed that there is generally a variation of ± 10% in the daily production capacity of the production line. The average daily production capacity is the same as the carry-in capacity.
(2) Carry-in work and carry-out work are performed independently.
(3) The number of carry-in coils and the number of carry-out coils, the carry-in completion date, and the carry-out completion date are the same in Comparative Example 1 (conventional method), Comparative Example 2 (mixed storage method), and Example 1 (present invention). is there.

  In order to calculate the number of safety stock coils, first, the conveyance capacities of Comparative Examples 1 and 2 and Example 1 were calculated. In the mixed storage method of Comparative Example 2, the time for sorting work to move another lot to another position in the yard is included in the work time for carrying out the coil of the lot to be carried out. For this reason, the mixed storage method of Comparative Example 2 requires a longer unloading operation than the conventional method of Comparative Example 1 and the method of the present invention of Example 1. Therefore, in this verification 2, from the knowledge of the inventors of the present application, when the carry-out time by the conventional method of Comparative Example 1 and the method of the present invention of Example 1 is 6 (ratio), the mixed storage method of Comparative Example 2 is 8 (ratio) time was required.

  And the carrying-in ability of Comparative Examples 1 and 2 and Example 1 is a ratio of 8 coils / day, the carrying-out ability of the conventional method of Comparative Example 1 and the method of the present invention of Example 1 is 8 coils / day, and Comparative Example 2 The simulation was performed by setting the carry-out capacity of the mixed storage method to 6 coils / day, and the first time with the 48-coil carry-out completion date being 8 days later and the second with the 48-coil carry-out completion date being 22 days later. The result is shown in FIG.

  As shown in FIG. 17, in the mixed storage method of Comparative Example 2, the carrying-out period is a cycle of 8 days and the carrying-in period is 6 days. In the conventional method of Comparative Example 1 and the method of the present invention of Example 1, the carrying-out period is Was 6 days, the carry-in period was 6 days, and the idle period was 2 days. As a result, it was found that in the mixed storage method, it is necessary to start the carry-out work immediately after the carry-in work is completed. Here, assuming that the production line has a variation of ± 10%, the mixed storage method of Comparative Example 2 requires a safety stock of 10% (5 coils) of the number of carry-in coils. On the other hand, in the conventional method of Comparative Example 1 and the method of the present invention of Example 1, the carry-in work is completed on the 15th day before the carry-out work start date (the 16th day) even if the manufacturing ability is −10%. Therefore, safety stock is not necessary.

  From the above verification, according to the method of the present invention, the number of stored coils can be increased by a little less than 30% compared to the conventional method. The mixed storage method can also increase the number of stored coils as compared with the conventional method, but the mixed storage method takes time to carry out the coils, so that the number of coils carried out from the coil place per unit time decreases. Or the unloading time per coil becomes long. As a result, the number of safety stock coils has increased, and the actual storage space has been increased by about 30% in the method of the present invention, and by 20% in the mixed storage method. In addition, according to the mixed storage method, there is a case where the stop operation of the placement work for correcting the erroneous shipment may occur several times per year, but the method of the present invention can generally prevent the occurrence.

  Therefore, the method of the present invention can increase the number of stored parts without lowering the coil carry-out ability compared with the conventional method, and can enable a site operation suitable for the production and shipment of coils. I can say that. In addition, the method of the present invention has a lower storage capacity than the mixed storage method, but can maintain a high transfer capacity, and it can be said that this method is also suitable for coil production and shipment.

  The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to such examples. It is obvious that a person having ordinary knowledge in the technical field to which the present invention pertains can come up with various changes or modifications within the scope of the technical idea described in the claims. Of course, it is understood that these also belong to the technical scope of the present invention.

DESCRIPTION OF SYMBOLS 1 Place management system 5 Support member 10 Coil 10a Coil hole 20 RFID tag 30 Conveyance apparatus 31 Notification part 32 Fork part 33 Real address acquisition part 34 RFID reader 35 Position sensor 37 Real address calculation part 39 Carry-in position check part 100 Place management apparatus 110 Information processing section 111 Shipping lot determination section 112 Work lot determination section 113 Design place code setting section 114 Transport work instruction section 115 Update processing section 116 Input section 120 Data storage section 121 Shipping table 123 Placement table

Claims (6)

A place management method by a place management system for a place where a wire rod or steel bar coil is stored,
The placement area can arrange the coils in a row with the penetration direction of the coil holes aligned in the depth direction, and can arrange a plurality of the horizontal and vertical directions adjacent to the coil radial direction. The actual position of the place represented by the column representing the horizontal position and the stage representing the vertical position is the real address,
A plurality of the coils having the same shipping date and shipping destination as the same shipping lot are assigned to the coils, and a plurality of the manufacturing timings are the same in the same shipping lot. The work lot number is assigned to the coil as the same work lot,
A design placement code setting step for calculating a loading position of the placement for loading the loading coil and setting a design placement code representing the loading position of the loading coil for the loading coil that is the coil loaded into the placement; and ,
Incoming coil registration step of registering in the place table in association with the design place code of the carry-in coil, the shipping lot, and the work lot for the real address,
Based on the design placement code of the carry-in coil specified by the work instructor, obtain the actual address corresponding to the design placement code from the placement table and the coil number of the coil to which the design placement code is assigned, A loading instruction step of notifying the worker of the real address;
Including
In the design place code setting step,
About the carry-in coil of the same work lot,
Based on the number n of coils in the work lot of the carry-in coil and the number C of coils that can be stored in one real address, the number of storage rows Cp necessary for storing the carry-in coil in one work lot To calculate
Based on the number N of storage locations and the storage column number Cp, the first column number P ₀ required to store the storage column number Cp is calculated,
In the section where the coil is not arranged in the placement area, a section where the number of first-stage columns is equal to or greater than the number of first-stage columns P ₀ required to store the storage column number Cp is loaded into the loading coil. Determine as a section, and set the coil number of the carry-in coil and one design place code in the real address corresponding to the carry-in section in the place table,
Place management method.   For each design site code set in the design site code setting step, whether the maximum value of the number of coils that can be stored in the section to which the design site code is assigned is equal to or greater than the number of the carry-in coils. The placement management method according to claim 1, further comprising a design placement code determination step of determining whether or not. In the storage area, an RFID tag in which a real address code that can identify the real address is recorded is installed,
The conveyance device that conveys and unloads the coil with respect to the place is provided with an RFID reader that reads the real address code recorded on the RFID tag,
In response to the carry-in instruction step, when the worker carries the carry-in coil to the place by the carrying device, it is recorded in the RFID corresponding to the carry-in position of the carry-in coil by the RFID reader of the carry device. A real address code reading step for reading the real address code;
In the storage table, the design storage code corresponding to the real address specified from the actual address code was compared with the design storage code specified by the work instructor in the carry-in instruction step, and compared. When the design place code is different, a notification of a re-instruction for carrying-in work of the carry-in coil to the operator, a loading position check step,
The placement management method according to claim 1 or 2, further comprising:   A coil that registers the storage position of the coil in the placement table by associating the coil number of the carry-in coil with the real address where the coil is carried in when the design place code compared in the carry-in position check step is matched. The storage location management method according to claim 3, further comprising a storage location registration step.   When unloading the coil to be unloaded from the storage site, at least the real address corresponding to the shipping lot is obtained from the storage table based on the shipping lot specified by the work instructor, and the real address is The placement management method according to any one of claims 1 to 4, further comprising a carry-out instruction step for notifying a person. The placement management according to claim 5, wherein after the coil is carried out by the carry-out instruction step, at least the coil number associated with the real address of the placement from which the coil has been carried out is deleted from the placement table. Method.

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