JP2733925B2 - Production ratio control method and apparatus based on production results - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a production ratio control method and apparatus based on production results, and particularly to production in a factory or the like that manufactures a plurality of types of vehicles and engines for processing and assembly work on the same line. The present invention relates to an improvement in a ratio control method and apparatus. [Related Art] In a production process of a work in a factory that manufactures vehicles, engines, and the like, a plurality of types of works are often manufactured on the same line in each process. In such a case, it is necessary to supply various works to each process line at an appropriate ratio according to the degree of difficulty in assembling the works and the types of parts used. Here, an example of such a conventional production process will be described with reference to the drawings. As shown in FIG. 7, the work 100 is stocked in the front stock 10 for each type. The workpiece 100 stocked in the front stock is the front stock stopper 12
Is supplied to the processing step 14 via the. The work 100, which has been processed in the processing step 14, is distributed by the distribution device 16.
The work is classified according to the type of the work and is carried into the post-process stock 18. Then, the work 100 in the post-process stock 18 is supplied to the post-processing process via the post-process stock stopper 20. Here, the supply of the work 100 to the processing step 14 by the front stock stopper 12 is controlled by the control device 22. The post-process stock 18 has a specified amount detection limit switch 24 for detecting the stock amount of each type of the work 100.
And a pool over detection limit switch 26. Here, if the stock amount of the work 100 in the post-process stock 18 is less than the specified amount, the work
100 means that the stock amount is small, and if the stock amount of the work 100 is over the pool, it means that the stock amount is large. Next, the configuration of the control device 22 of the conventional example will be described. As shown in FIG. 8, the control device 22 includes an input interface 24, a supply work operation control unit 26, a supply order data memory 28, and an output interface 30. A signal a is supplied to the supply work operation control unit 26 via the input interface 24. The supply work operation control unit 26 reads data from the supply order data memory 28, and supplies a supply command based on the data. b is output via the output interface 30. The supply command a is a detection signal from the specified amount detection limit switch 24 and the pool over detection limit switch 26. Then, the supply of the work 100 into the processing step 14 by the previous work stopper 12 is controlled by the supply command b. Here, the supply order data memory 28 has data as shown in FIG. In other words, data on the type of the work 100 and whether the work is an unreserved seat is stored as coded work supply order data in which the type of the work 100 and whether the work is an unreserved seat are coded for each order of the frame Nos. In this case, the coded work order data is the number corresponding to the type of work, and 100 if the seat is unreserved.
Are formed by adding. Next, the operation of the control device 22 will be described with reference to the flowchart of FIG. When the work 100 is loaded, the supply work operation control unit 26 first reads out the coded work supply ordering data from the supply order data memory 28 (code reading). Then, it is determined whether the coded work supply sequence data is an end code (end code?). If this coded work supply sequence data was end code,
Since the supply order data currently being read has been completed, the frame No. is set to 1 (frame No. = 1), and the process proceeds to reading out the next data. If it is not the end code, the vehicle type is determined from the coded work supply sequence data (vehicle type determination, vehicle type = N). If the vehicle type is N, it is checked whether the stock amount in the post-process stock 18 of the vehicle type N, that is, whether the pool over detection limit switch 26 is turned on (N stock pool over?). If the pool is over here, it is better not to supply the work 100 of this model to the machining process 14, so no supply instruction is given,
The process proceeds to reading the coded work supply order data of the next frame (frame No + 1). If the pool is not over, it is determined whether or not the code is an unreserved seat (unreserved seat?). Here, if the seat is not a free seat, it is better to insert the work 100 into the machining process 14.
Work input instruction output). If the code indicates that the seat is unreserved, it is determined whether the stock of the vehicle type N is less than a specified amount (less than the specified amount of N stock?). If this is not less than the specified amount, it is better not to put the work 100 into the supply step 14, and the process shifts to code reading of the work. If the amount is less than the prescribed amount, it is better to insert the work, so that a work input support is output (output of a work input instruction of vehicle type N). The process returns to reading the code of the next frame No. (frame No. + 1). The work input instruction is supplied to the front stock stopper 12 as a supply command b). When the frame No. becomes equal to or larger than the maximum frame No. (frame No. over?), The frame No. is returned to 1 (frame No. = 1), and reading of the next data is started. In this way, the control device 22 controls the supply of the workpiece 100 to the machining process 14 based on the supply sequence data of the workpiece and the stock state of each type of the workpiece 100 in the post-process stock 18. Incidentally, such a production ratio control device is disclosed in, for example,
61-265251 and JP-A-61-265252. [Problems to be Solved by the Invention] In such a conventional method, the production ratio is controlled by the quantity of each type of the work 100 in the rear stock 18. For this reason, there has been a problem that, when the production result is deviated from the production plan, the deviation cannot be eliminated. In other words, in each processing step 14, there is a plan for how much each type of work is to be produced. The data on the work supply sequence is determined based on such a production plan. However, due to the control described above, actual production deviates from this plan. And
The conventional method could not eliminate this shift. [Related Technology] The applicant of the present invention has proposed a technology related to this application in Japanese Patent Application Laid-Open No. 62-66959. In this method, the ratio of each type of work in the machining process 14 is calculated, and the production ratio is corrected based on the calculated ratio. However, even with this method, as described above, it is not possible to eliminate the deviation of the production result from the production plan. [Means for Solving the Problems] A production ratio control method based on production results according to the present invention is directed to a production ratio control method for supplying a plurality of types of works to machining steps in accordance with predetermined supply sequence data. Determining whether or not the work is a free seat that can determine whether or not the work is supplied based on the production results, based on the supply sequence data, and the production results for counting the number of each type of work processed in the above-described processing process A counting step, and a step of comparing the count result in the production result counting step with a previously stored production plan for each work type in the machining step when the supply order data indicates unreserved seats. Determining whether to supply the work to the processing step based on the result; and And butterflies. Further, the production ratio control device based on production results of the present invention is a production ratio control device for controlling the supply of a plurality of types of works to a machining process. A supply order data memory storing data on whether or not the seat is a free seat that can determine whether or not to perform the work, a production plan memory storing the number of production plans for each type of work, and a work machined in the machining process. A production result counter that counts the number of workpieces for each type of work, a comparison operation unit that receives outputs from the production plan memory and the production result memory, and compares them, and a comparison operation unit that receives the output from the comparison operation unit and the supply order memory. A supply work calculation control unit that receives the output and determines whether or not to supply the work. [Operation] According to the production ratio control method of the present invention, the work is supplied to the machining process in accordance with the predetermined supply order data. Whether the work can be supplied is determined as follows. Here, the unreserved seat indicates that it is possible to determine whether or not to supply the work according to the production results. First, the number of each type of work machined in the machining process is counted each time, and the actual production is counted, and a production plan for each type of work in the machining process is stored in advance. If the work supply order data for the work to be supplied to the machining process is unreserved, the production plan and the production result for the type of the work are compared, and the result of the comparison is used as a result of the comparison. It is determined whether or not to supply. Then, the input of the work into the machining process is controlled based on the determination result. As described above, whether or not to input a work is determined by comparing the production plan with the production results, so that the deviation of the production results from the production plan can be automatically corrected. According to the production ratio control device of the present invention, the supply order of the work, the type of the work, and the data indicating whether or not the seat is a free seat are stored in the supply order data memory, and the production plan for each type of the work is stored. Is stored in the production planning memory. Then, the production plan and the production result of the workpiece to be put in are compared by the comparison operation unit. Then, the supply work operation control unit determines whether or not the input work is possible based on the comparison result in the comparison operation unit and the supply order data from the supply order memory. For this reason, it is possible to automatically correct the deviation of the production result from the production plan. Embodiment An embodiment of the present invention will be described with reference to the drawings. FIG. 1 shows a block diagram of a control device 22 according to one embodiment of the present invention. In this embodiment, as in the case of FIG. 8, the control device 22 includes an input interface 24, a supply work operation control unit 26, a supply order data memory 28, and an output interface 3.
Has zero. The signal a of the detection data of the specified amount detection limit switch 24 and the pool over detection limit switch 26 of the post-process stock 18 in FIG. 7 is supplied to the supply work calculation control unit 26 via the input interface 24. The coded work supply order data as shown in FIG. 9 stored in the supply order data memory 28 is supplied to the supply work operation control unit 26. The output from the supply work calculation control unit 26 is
It is supplied to the front stock stopper 12 via the output interface 30 as a supply command b. Here, the control device 22 of this embodiment includes a production plan memory 40, a production result counter 42,
It has a comparison operation unit 44. The production plan memory 40 stores a production plan in the machining process 14, that is, a planned production number for each type of work. FIG. 2 shows an example of a memory configuration in the production plan memory 40. In this example, there are 1 to 6 types of vehicles, and the planned number of each type is stored. For example, the planned number of vehicles 1 is 350. Here, in this memory, two addresses are assigned to one vehicle type. And address 7000
Stores the lower data 50, and the address 7001 stores the upper data 03. Then, this data identifies that the planned number is 350 units. Further, the supply work calculation control unit 26 supplies a signal c regarding the type of the work 100 to be supplied to the production result counter 42. The production result counter 42 includes an up-counter unit having a reset function and a preset function, and one up counter is provided for each type of work.
When the signal c from the supply work calculation control unit 26 is input, the up counter of the work of the corresponding type is incremented by +1.
Is done. The contents of the production result counter 42 are cleared by resetting or presetting by the operator at the time of starting a production line or changing a production plan. The comparison operation unit 44 calculates the production plan ratio of each work from the production plan number input from the production plan memory 40. That is, the total number of production plans is calculated by summing the planned production numbers of the respective works, and the production plan ratio for each type of work is calculated by dividing the planned production number of each work by the total number. Then, the production plan ratio is calculated and stored after resetting or presetting. Further, the comparison calculation unit 44 calculates the production performance ratio of each work from the number of each work actually produced based on the input data from the production performance counter 42. That is, the production result rate is calculated by dividing the production number of each work at that time by the input production number of all the works. This production performance ratio is sequentially stored. Then, the comparison operation unit 44 compares the production plan ratio and the actual production ratio of the corresponding work based on the signal d from the supply work operation control unit 26. Note that this comparison may be performed by the supply work calculation control unit 26 outputting a work input instruction, or by including data on whether or not comparison is necessary in the signal d, and You may go only. In this way, the comparison operation unit 44 compares the production plan ratio and the production actual ratio, and the signal of the result is supplied to the supply work operation control unit 26. Each time the supply work calculation control unit 26 outputs the supply command b, the comparison calculation unit 44 recalculates the production actual ratio for all the works, compares each of the works with the production plan ratio, and I remember. Next, the processing in the supply work calculation control unit 26 will be described with reference to FIG. When the work input command b is input, first, the comparison operation unit
At 44, it is determined whether a comparison result between the production plan ratio and the actual production ratio has been obtained (comparison operation completed?). If the comparison operation is not completed, the process does not proceed until this operation is completed. If this has been completed, the coded work supply sequence data is read from the supply sequence data memory 28 (code read). Then, it is determined whether or not this code is an end code (end code?). If the code is an end code, the frame No. is returned to 1 (frame No. = 1), and the operation for the next data is started. If it is not the end code, it is determined whether or not the work can be supplied. That is, the vehicle type is determined from the coded work supply sequence data (vehicle type determination). Here, it is assumed that vehicle type = N. Then, it is checked whether or not the work of the vehicle type N is over-pooled in the post-process stock 18 (N-stock pool over). In other words, the pool over detection limit switch
If 26 is on, it indicates that the vehicle is over the pool. Therefore, if the pool is over, 1 is added to the frame number, and no instruction to input a work is given. If the pool is not over, it is next determined whether or not the code is an unreserved seat (unreserved seat?). Here, the unreserved seat indicates that it is possible to determine whether or not to supply the work according to the production results. If the seat is not an unreserved seat, it is better to insert the work, so a work input instruction is output (work input instruction output of vehicle type N). If the seat is an unreserved seat, it is next determined whether or not the stock amount in the post-process stock 18 of the work of the vehicle type N is less than a specified amount (less than the specified stock amount of N). That is, it is determined whether the specified amount detection limit switch 24 is on. If the stock amount is less than the specified amount, it means that the stock of the vehicle type N in the post-process stock 18 is small, so that the work input instruction is output. Further, when the stock amount is not less than the specified amount, it can be understood that the degree of freedom regarding the input destination of the work of this vehicle type is large. Therefore, in this case, control based on the production plan and production results is performed. That is, in this case, it is determined whether the production actual ratio of the work is larger than the production plan ratio (actual> plan). If the actual production ratio is larger than the production plan ratio, the production of the vehicle type is higher than the plan, and therefore, it is better to reverse this work input. Therefore, no input instruction is given. On the other hand, if the actual production ratio is smaller than the production plan ratio, this work is input to eliminate the difference between the actual production ratio and the production plan ratio. Then, such processing is sequentially repeated for the data of each frame No.
When the frame number reaches the upper limit value (frame number over?), The frame number is reset to 1 (frame number = 1), and the next comparison is started. As described above, according to the control method of this embodiment, in determining whether or not to input a work, input control of the work is performed in consideration of a difference between a production result and a production plan for a work having a high degree of freedom. For this reason, the deviation of the production results from the production plan can be effectively eliminated. Here, the fourth comparison operation in the comparison operation unit 44 is described.
Description will be made based on the drawings. First, it is determined whether the calculation in the supply work calculation control unit 26 has been completed (supply work calculation end). If the calculation is not completed, the process waits until the calculation is completed. When the calculation is completed, the number N for the vehicle type is reset to 0 (N = 0). Then, 1 is sequentially added to N, and calculations are performed for all the vehicle types from the vehicle type 1. That is, the production plan ratio of the vehicle type N (vehicle type 1 in the first case) is calculated from the production plan number of each work stored in the production plan memory 40 (vehicle type N production plan ratio calculation).
Next, an actual value of the production ratio of the vehicle type N is calculated from the value of the production actual counter 42 (vehicle type N production actual ratio calculation). Then, the two data are compared (vehicle type N plan actual result comparison). The result obtained by such comparison is compared with the comparison operation unit 44.
(N model comparison result store). Such calculation and storage are performed for all vehicle types by sequentially adding 1 to N, and comparison results for all vehicle types are stored. Next, a control device 22 according to another embodiment of the present invention will be described with reference to FIG. In this embodiment, the control device 22 has a work number counter 46 in addition to the control device 22 shown in FIG. Then, using the work number counter 46, the supply control of the supply work is performed in consideration of the ratio of each type of the work in the machining process 14. In this embodiment, a signal e about the processed workpiece in the processing step 14 to be input to the production result counter 46 is supplied from the input interface 24.
That is, in this example, the post-process stock stopper 20
The data on the workpiece to be supplied to the next processing step in step (1) is input to the input interface 24. For this reason, the count in the production result counter 42 is the number of works carried out from the post-process stock 18, and even if a work is extracted due to quality defects or the like in the own process, the count of the production result may be inconsistent. There is no effect. The control device 22 shown in FIG. 1 has an advantage that the signal line from the post-process stock stopper 20 is unnecessary and the whole device is simplified. Also, a signal from the post-process stock stopper 20 may be used as a count signal of the production result counter 42 in FIG. 1, or a signal from the supply work operation control unit 26 may be used as a count signal of the production result counter 42 in FIG. a may be used. Next, the operation of the supply work calculating section 26 in the embodiment of FIG. 5 is shown in FIG. In the flowchart of FIG. 6, a comparison of the ratio of each type of work in the machining process 14 is added to the flowchart of FIG. That is, in the previous stage of comparing the actual production ratio and the production plan ratio (actual> plan?), The in-process ratio is compared with the set ratio (in-process ratio>
Setting ratio). This comparison is performed by comparing the ratio for each type of work in the process obtained by the work number counter 46 with the set ratio for each type of work obtained from the supply order data. If the in-process ratio is larger than the set ratio, the input for the vehicle type is inappropriate, and the control is performed so that the work is not input. By such a method, fine control can be performed in consideration of the in-process work ratio. The control according to the work ratio is proposed in Japanese Patent Application No. 62-66959 as described above. In the two controls according to the present invention, the production ratio is corrected by giving priority to the flow state of the production line at that time. That is, the deviation between the production plan and the production result is corrected only when the degree of freedom is high. As a result, the work required at the point of time can be produced in just time, and the stop of the next process line due to a missing part can be effectively prevented. [Effects of the Invention] As described above, according to the production ratio control method and apparatus based on production results according to the present invention, it is possible to automatically produce a production ratio so that the difference between production results and a production plan is reduced. In addition, the work production ratio in the production line can be optimized.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing an outline of a control device 22, FIG. 2 is an explanatory diagram of the contents of a production planning memory 40, and FIG. FIG. 4 is a flowchart for explaining the operation of the comparison operation unit 44, FIG. 5 is a block diagram showing an outline of a control device 22 according to another embodiment of the present invention, and FIG. Fig. 7 is a flow chart for explaining the operation of the supply work calculation control unit in Fig. 7, Fig. 7 is a configuration diagram schematically showing a part of a production line, Fig. 8 is a block diagram showing a configuration of a control device 22 in a conventional example, Fig. 9 Is an explanatory diagram showing the contents of the supply order data memory 28, and FIG. 10 is a flowchart showing the operation of the supply work operation control unit 26 of the conventional example. 14 Machining process 22 Control device 28 Supply sequence data memory 26 Supply work calculation control unit 40 Production plan memory 42 Production counter 44 Comparison operation unit

Claims (1)

(57) [Claims] In a production ratio control method for supplying a plurality of types of works to a machining process in accordance with predetermined supply order data, it is possible to determine whether or not the work is supplied based on production results based on supply order data for the work. A step of determining whether or not a seat is a free seat; a production result counting step of counting the number of workpieces processed in the machining step for each type; and a production result counting step when the supply order data indicates a free seat Comparing the count result with the production plan for each work type in the machining process stored in advance, and determining whether to supply the work to the machining process based on the result of the comparison. A production ratio control method based on production results. 2. In a production ratio control device that controls the supply of multiple types of workpieces to the machining process, data on the order of supply of workpieces, types of workpieces, and data on whether or not the workpieces are unreserved seats can be determined based on production results A supply order data memory for storing the number of production plans for each type of work, a production plan memory for counting the number of workpieces processed in the machining process for each type of work, A comparison operation unit that receives outputs from the production plan memory and the production result memory and compares the two; and a supply work that receives outputs from the comparison operation unit and the supply order memory and determines whether to supply the work. A production ratio control device based on production results, comprising: an arithmetic control unit;