JP2554711B2 - Production instruction switching method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial field of application) The present invention relates to a production instruction switching method. More specifically, in a high-mix low-volume production system, the production of an old model is discontinued and the production of a new model is launched. The present invention relates to a method for automatically switching production instructions.

(Prior Art) In a high-mix low-volume production system, switching from an old model to a new model is relatively frequently performed due to a change in the type of similar products. In this switching, after the model change is decided, the number of remaining discontinuation of the old model (remaining production number) is fixed, and the number of remaining discontinuation is subtracted each time the production instruction of the product is issued, which is zero. The production instructions for the new model will be given to the production line when it becomes.

(Problems to be solved by the invention) However, in the conventional art, it is necessary to monitor a production planer so as not to give a production instruction for an old model to a production line only when the number of remaining discontinuances of the old model is relatively small. It is common, and production instructions given before this monitoring sometimes produced extra old models. In addition, even when subtracting the number of remaining cutoffs, there is a problem that a calculation error is likely to occur because it is manually performed.

Furthermore, when the production of a new model is started immediately after the number of remaining discontinuation becomes zero, the assembly modeler often makes a mistake in the assembly process to attach the parts of the old model to the product of the new model. As a result, there were inconveniences such as the occurrence of defective products and the need for a constant monitoring system. In particular, in the case of model change, the old and new models are the same type, and the production line does not provide effective means for distinguishing the old and new models, which is a major cause of defective products.

The present invention has been proposed in order to solve the above problems, and an object of the present invention is to perform subtraction of the number of remaining cutoffs, management of the cutoff start-up time, and start-up in the cutoff start-up processing accompanying the model change. It is an object of the present invention to provide a production instruction switching method that automates product model identification and the like at the time to prevent production of surplus products and generation of defective products.

(Means for Solving the Problems) In order to achieve the above object, the present invention provides a product name to be switched from an old model to a new model, a production discontinuation start time and the number of remaining discontinuation of the old model, and an old model. The start-up time from the end of the production of the new model to the start of the production of the new model, the start-up end time of the new model is stored in advance in the production plan instructing device as a stop-up start-up table, and after the stop-starting time, Each time a product production instruction is given, the remaining number of cutoffs is decremented, the time when the remaining number of cutoffs becomes zero is the end time of the cutoff, and the time when the start time is added to this end time of the cutoff is the start time of the start. As a result, these discontinuation end time and start-up start time are automatically stored in the discontinuation start-up table. When a production instruction is issued and a surplus product of the old model is produced, an alarm is issued and a rising mark is added to the product for which the production instruction is given after the start-up start time and before the start-up end time. It is characterized by doing.

(Operation) According to the present invention, after the time when the model change is decided for a certain product, the production planner changes the model name,
By inputting the cutoff start time, the number of remaining cutoffs, the start-up time, and the start-up end time in the cut-off start-up table of the production planning instruction device, Management etc. is performed automatically, and when an old model surplus product is produced, an alarm is automatically issued. Further, at the time of start-up, a rising mark is given to the product of the new model, and this mark is also notified to the production line, so that the line worker can distinguish the new model from the old model.

(Example) An example of the present invention will be described below with reference to the drawings.

First, FIG. 2 shows an overall production system to which the present invention is applied. This production system is for assembling, inspecting, etc., a high-mix low-volume production product such as an automobile engine. is there.

In FIG. 2, 1 is a production management system including a host computer, 2 is a production plan instructing device including a mini computer system installed in a factory, 3 is a data way such as a LAN through an optical cable, and 41 to 44 are production plan instructions. A data terminal for exchanging production instruction data, production performance data, etc. between the device 2 and the assembly line 51 or inspection line 52,
5 is a production line including an assembly line 51 and an inspection line 52, and 6 is a product warehouse.

Here, the production plan instructing device 2 is the production management system 1
A data processing device 21 such as a minicomputer connected online or offline with a storage device 22, a man-machine interface 23 connected to the data processing device 21,
It is composed of a printer 24 and an alarm device 25. In addition, the data processing device 21 is provided with a production instruction switching means 26 including software for executing a series of switching processes including an old model production discontinuation process and a new model production start process, which will be described later.

In this embodiment, the data processing device 21 and the storage device 2
2, the man-machine interface 23, the printer 24, and the alarm device 25 have been described as the components of the production plan instructing device 2, but each of these components is not merely a production plan instruction, but facility operation management and production performance management, Various kinds of management, control, alarm output, etc. associated with production of products such as quality control can be performed.

Next, the abortive start-up process from the old model to the new model in this embodiment will be described with reference to the flowchart of FIG. 1 and FIG.

In FIG. 1, the data processing device 21 first retrieves a product name to be produced (in-process instruction) from a production sequence table created in advance by an instruction from the production line 5 (step
S1). The production order table is stored in the storage device 22 or the like. Next, it is determined whether or not the product name is registered in the abort launch table (S2).

This discontinuation chart shows the product name, the product name, and the product name at any time after the model change was decided.
It is created by the production planner inputting the production discontinuation start time of the old model, the number of remaining discontinuation, the production start time and the start end time of the new model through the man-machine interface 23. The product is displayed on the display for each product and stored in the storage device 22 or the like after the input.

Such a cut-off start-up table is configured, for example, as shown in the following Table 1 at the time before the cut-off start-up process is started.

In this table 1, the discontinuation start time is the discontinuation time of the discontinuation process for the old model of the product A, and the discontinuation remaining number is automatically decremented each time the production instruction of the old model is issued. Has become.

Further, the termination time is initially blank, and the time when the remaining number of terminations becomes zero is automatically input. In addition, the start-up time is set in advance as a margin time from the end time of the discontinuation until the production of the next new model is instructed, and the workers of the assembly line 51 and the inspection line 52 can change the time from the old model within this time. Prepare the parts, tools, inspection tools, etc. required for the change to the new model. The start-up start time is initially blank and means the time to start production of the new model, and the start-up end time means the end time of the start-up process of the new model, that is, the time when a series of model switching processes ends. There is.

In the previous step S2, if the product to be discontinued is A, since this product A is registered in the discontinuation table, whether the current time has passed the discontinuation start time in the next step. It is determined whether or not (step S3). If the product A is not registered, the model change is not performed, and an in-process instruction for the product A is issued to the assembly line 51 (at step S9).

In step S3, if the current time has passed the abort start time, it is determined in the next step whether or not the abort end time is stored in the abort start-up table (at step S4). If the current time is before the cutoff start time, the process proceeds to step S9.

In step S4, if the termination time has not been stored yet, the process is currently in the process of termination, and thus the number of remaining suspensions in the termination table is decremented each time a production instruction for the product A is issued (step S5). Then, it is judged whether or not the remaining number of cutoffs is zero (S6 of the same),
If it is not zero, the in-process instruction for the product A is given to the assembly line.
Send to 51 (same S9). On the other hand, when the remaining number of aborts is zero, the current time is automatically stored in the abort start-up table as the abort end time (at step S7).

Next, the start-up start time, which is the time obtained by adding the start-up time (3 hours) to this stop-end time, is automatically stored in the cut-off start-up table (at step S8), and the process proceeds to step S9.

If the termination time has already been stored in the previous step S4, that is, if the termination processing has ended, it is next determined whether or not the current time is before the start-up time (same). S10). Here, before the start-up start time, the number of remaining cutoffs is decremented every time the production instruction of the product A is issued. At this time, the number of remaining cutoffs is already zero due to the end of the cutoff processing. Therefore, the number of remaining cutoffs becomes negative due to the above decrement (S11 of the same).

This state is an abnormal situation where the production of the old model is continuously instructed within the startup time until the termination of the old model and the startup of the new model is started. In addition to being able to grasp the number of units produced, in the next step an alarm is issued by the alarm device 25 in FIG.
Go to 9.

Further, if the current time is after the start-up start time in the previous step S10, it is determined whether or not the next step current time is before the start-up end time (step S13).
If it is not before the start-up end time, that is, if it is after the start-up end time, the start-up process is completed and the process proceeds to step S9. Therefore, in order to make the operator of the production line 5 recognize that the product A currently being produced is a new model, an appropriate rising mark is added to a part of the product model discrimination label. 5 will also be notified (S14 of the same). As a result, the line worker can clearly recognize that the product A being produced is a new model, and thus it is possible to prevent an error in assembling parts or the like.

If the start-up end time has already passed in step S13, the aborted start-up process associated with the model change of the product A ends at the start-up end time without adding a new start-up mark.

In the above embodiment, the case where the production line is single has been described, but the present invention can be applied by a single production plan instructing device even when the types of various products are changed in a plurality of production lines. Also, the type of product is not particularly limited to automobile parts and the like.

(Effect of the invention) As described above, according to the present invention, the production planner or the like simply inputs the conditions such as the product name, the cutoff start time, and the number of remaining cutoffs related to the model change before the cutoff start-up process. It is possible to automatically perform processing such as subtraction of the number of remaining cutoffs, management of end time of cutoffs and start time of start-up, alarm output at the time of production of surplus products, and addition of rising marks to new models. Therefore, there is an effect that a calculation error of the number of remaining cutoffs does not occur, and the production of surplus products of the old model and the generation of defective products of the new model can be prevented in advance without artificially constantly monitoring the production line.

[Brief description of drawings]

FIG. 1 shows an embodiment of the present invention. FIG. 1 is a flowchart showing a cut-off start-up process, and FIG. 2 is a configuration diagram of a production system. 1 ... Production management system, 2 ... Production plan instruction device 5 ... Production line, 21 ... Data processing device 22 ... Memory device 23 ... Man-machine interface, 24 ... Printer 25 ... Alarm device, 26 ... … Production instruction switching means 51 …… Assembly line, 52 …… Inspection line

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Tadashi Naito 1 Toyota-cho, Toyota City, Aichi Prefecture Toyota Motor Co., Ltd. (72) Inventor Kiyonobu Takahashi 1-1 Tanabe Nitta, Kawasaki-ku, Kawasaki-shi, Kanagawa Fuji Electric Incorporated (72) Inventor Shoji Sawa 1-1 Tanabe Nitta, Kawasaki-ku, Kawasaki-shi, Kanagawa Fuji Electric Co., Ltd. (56) Reference Japanese Patent Laid-Open No. 2-30462 (JP, A)

Claims (1)

(57) [Claims] 1. In a production instruction switching method for switching a production instruction for a production line from an old model to a new model by a production system for a high-mix low-volume production product using a production plan instruction device, the product name to be switched, The production discontinuation start time and the number of remaining discontinuation of the old model, the start time from the discontinuation of the production of the old model to the start of the production of the new model, and the discontinuation time of the start of the new model are discontinued to the production planning instruction device It is stored in advance as a table, and after the discontinuation start time, the number of remaining discontinuation is decremented each time a product production instruction is given, and the time when the number of remaining discontinuation becomes zero is the discontinuation end time, and this discontinuation end The time obtained by adding the start-up time to the time is used as the start-up start time, and the end time and the start-up time The start-up time is automatically stored in the abort start-up table, and when the product production instruction is given within the start-up time and the surplus product of the old model is produced, the alarm is issued and the start-up start time is set. A production instruction switching method, characterized in that a rising mark is added to a product for which a production instruction has been given after that but before the start-up end time.