JP3380279B2 - Manufacturing management system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [0001] BACKGROUND OF THE INVENTION The present invention relates to a vehicle production line and the like.
The present invention relates to a manufacturing management system suitable for use. [0002] [Prior Art] FA (Factory Automation) technology
The technique is to improve product quality, reduce manufacturing costs and produce
This has brought great achievements to the manufacturing industry in terms of improved performance. This
According to the production system that introduced the FA technology of
Work related to product manufacturing, such as transport of standing articles and control of processing
All are performed under the control of a computer. Sand
In addition, under the control of the computer,
Machines are sequentially transferred to each processing machine.
The determined control data is provided. Like this
The target product can be automatically produced without
It is. For processes that require strict control,
Results of work performed by the processing machine, for example, bolt tightening
Is measured by a sensor, etc., and this measurement result is
Or whether it matches the common set value prepared for each part
Is inspected. And the group that passed the inspection
Only the stand is passed to the next step. Work in this way and its
Surveillance is integrated and stable, high quality products
Produced. [0003] However, the production line
Therefore, the same line is used for assemblies having various specifications.
In case of production with different specifications at the inn
In such a case, all control is performed only by the computer
It may not be possible to do so. Ie computer
Overload, slowing down processing speeds and
This is because there is a risk of lowering the efficiency of the component. like this
Information to reliably identify the assembly to address
Information (barcode, etc.) on the assembly and read the information.
Sensors are installed at each site in the production line,
Computer identifies the assembly via these sensors
And send control data suitable for the assembly to the processing machine.
A method of performing work is adopted. [0004] However, products with such many specifications are not supported.
Production line,
In some cases, work processes involving workers are provided. So
In the case of, the identification work of the assembly object by the sensor as described above
In many cases, the operator operates the identification device. so
When this happens, the worker inadvertently forgets the identification work,
The result of the work performed by the machine is regarded as the work result of another
May be judged. The present invention has been described above.
This was done in consideration of the circumstances, and the work of identifying the assembly
Identification is ensured when the
Provide a production management system that does not delay work
It is intended to be. [0005] SUMMARY OF THE INVENTION Manufacturing control according to the present invention
the system,Flow through a manufacturing line consisting of multiple manufacturing processes
Assembly identification means for identifying the assembly to be installed
Bar code reader) and in the manufacturing process
Assembly detection means for outputting the result of work performed on the assembly
(E.g., the ETC wrench of the embodiment)
Manufacturing of control means (for example, the work terminal WT of the embodiment)
Have for each process, work on the work control means for each manufacturing process
Instruction and data output from the work control means.
Storage means for storing data (for example, the file of the embodiment)
Manufacturing control provided with a server FSn (n = 1 to 3)
The work control means includes:
A work instruction from a step and a work output from the assembly detecting means.
A data holding unit for writing the work result
Means for assembling a new assembly by the assembly identification means;
Identified or the work result is stored in the data
If a predetermined time has passed since the data was written to the
Work in which the contents of the data holding unit are written in the storage means
Determine whether or not it complies with the instructions, and
Output the contents of the data holding unit to the storage means,
If it does not conform, a warning is issued by warning means and the
To select whether to execute the output to the storage means
Is characterized by. [0006] According to the above construction, an assembly is placed on the production line.Throw
Is inserted, the assembly goes through each process in the production line.
When the assemblyThe assembly is identified
You.And the assemblyBy means of identification,
Of each part incorporatedIdentification is performed and stored in the storage means.
The work instruction is written to the work control means. Also,
Business control means,Work detection results for work on the assembly
Write the result data to the data holding unit.on the other hand,new
AssemblyAssembled objectIdentified by identification means or
At a predetermined time after the work result data is written to the data holding department
If the time has passed,Work controlMeans of the data holding department
The contents conform to the work condition data read from the storage means
It is determined whether or not. Data if applicable
Outputs the contents of the holding department to the management means, if it does not conform
Is warned by the warning means, and the work result data is stored in the storage means.
Select whether to execute the output of the data. [0007] An embodiment of the present invention will be described below with reference to the drawings.
I will tell. FIG. 1 shows a manufacturing control system according to an embodiment of the present invention.
FIG. 2 is a block diagram illustrating a configuration of a system. This production management system
Tem is a safety device (Supplemental R
Estraint System (hereinafter abbreviated as SRS)
Applies to the SRS assembly line
Installed in the factory with equipment for carrying out each operation
You. First, a description will be given of a manufacturing management system.
Now, the SRS assembly line will be described. SRS is below
It is composed of the following five types of parts. Dash sensor-R Dash sensor-L SRS unit Cable reel Module assembly The SRS assembling line is used to assemble the above components.
It has multiple processes for performing
Then, basically one type of work is performed. Also, the above parts are
It is prepared in advance for each process corresponding to each. [0010] The vehicle to which the SRS is to be assembled (hereinafter referred to as
Types of vehicles are called SRS specification vehicles).
Of the SRS to be assembled according to each specification
The composition is different. For example, a vehicle with a certain specification has the above five items.
It is necessary to assemble the SRS that includes all
Some parts are not required for vehicles. This SRS group
In the attached line, each time a vehicle arrives at each process,
Identification is performed, and the vehicle is identified based on the identification result.
Judgment on whether or not parts prepared for the process should be assembled
Done. Also note that differences in assembled parts due to differences in specifications
Show. With such control, each vehicle is required
Only necessary parts are assembled. Each of the above components has a serial number.
Code. Each part is assembled on the vehicle
The serial number will be collected when
ing. In each step, bolt tightening work,
When performing assembly work such as mating work, tighten
Information indicating the result of the work, such as the mounting torque value and
Is to be taken. The manufacturing management system according to this embodiment
The stem thus has a serial number and
Collect work status at the time of assembly as work data
And collect collected work data for each vehicle
Things. In this factory, the SRS assembly lane described above is installed.
As the in, first to third lines are installed. Engineering
Each vehicle brought into the yard will have one of these lines
Introduced to one of the lines, assembling SRS as necessary
Injuries are made. Next, the configuration of the manufacturing management system will be described.
In FIG. 1, FS1 to FS3 are first to third lines.
Is a file server provided corresponding to each of. This
Each of these file servers FS1 to FS3
Information for work control or the work data
I have various files to store. CT1 and CT2 are communication terminals, respectively.
ALC (Assembly) that controls the entire automobile production line
le Line Control; assembly line control)
Computer HST via a communication line. communication
Terminals CT1 and CT2 duplex the communication function
The communication terminal is provided below.
Terminal CTn. A vehicle is put on the SRS assembly line
AF-ON, which is received data about the vehicle
Data is transmitted from the host computer HST. Through
The communication terminal CTn transmits the AF-ON data transmitted in this manner.
Receive data. In addition, the vehicle is disconnected from the SRS assembly line.
When turning in and off, the vehicle on the SRS assembly line
Communication terminal information as AF-OFF data
It is transmitted from CTn to the host computer HST. The work terminals WT, WT,...
One unit is arranged for each process to be performed. Each work terminal
As shown in Fig. 3, the
Used for bar code readers 1 and 2 and for tightening work
ETC wrench 3 or constant torque wrench 4
And a device such as a fitting mouse 5 used for the connection.
In each step, among these,
Only the necessary devices are connected. The work terminals WT, WT,...
Performs the following functions in the process under the jurisdiction of Control of the work to be performed in the process under their control. This
Controls include the identification of incoming vehicles, the determination of workability,
Judgment of work contents, judgment of parts that can be assembled, and tightening work
(Electric torque control) wrench or constant
The control of the wrench is included. The work actually performed in the process under their control
Confirmation, specifically the value of the torque in the tightening work,
State of mating part after mating work, serial number of assembled parts
Etc. collection. Forming work data based on the collected results. Whether the work was performed in a manner that satisfies the predetermined criteria
Display of judgment and judgment result. The management terminal MTn (n = 1 to 3)
One for each line, and one for each line
Manage files. Others are installed for each line n
The terminals that have been inspected are the MIT middle inspection terminal, the FIT complete inspection terminal,
There are a maintenance terminal MET, an adjustment terminal ADT, and the like. Ma
N1 and N2 each form a network
Data between each terminal device in this manufacturing management system
Used as a transmission path. Next, in this manufacturing control system,
The various files to be executed will be described. Each file server
FSn (n = 1 to 3) is a management file for each line n.
The ALC received files F1 and A1 shown in FIG.
LC transmission file F2, SRS work table F4 and
It has an inspection unit data file F6 and the like. Less than,
The contents of the main file will be explained. (1) SRS work table F4 The SRS work table F4 has the SRS assembly line
Work when assembling SRS parts into a vehicle
As shown in FIG. 4, the SRS symbol, SR
S symbol content, parts table data, tightening table data
And fitting table data. The parts table data is S for each SRS symbol.
Data that defines the components of the RS, up to N1
Can be defined. Each part table data contains the part name or
Indicates the work to be performed on the part (tightening / mating)
Data for the operator and the SRS symbol
And a symbol that specifies the parts that can be
It consists of the number of the process that performs the task and the search key. The tightening table data is composed of SRS parts.
This data defines the tightening work required for fastening.
Up to N2 items can be defined. Each tightening table data
Is defined for each SRS symbol, and
The information that specifies the details of the mounting work and the tightening torque range
Symbol, the number of the process in which the work is performed, and the search key
Consists of The fitting table data is stored in the vehicle.
Define the mating work required when assembling SRS parts
The data is defined in the same way as the tightening data. Theory
Tightening table data and mating table data
Also, just as in the case of parts table data, only necessary items
Is written to the field of each table data. Each work terminal WT has its own jurisdiction each time.
Parts in the work table F4 using the process number of the process as a key
Data, tightening data and mating data
Capture things. Tightening data and mating
The data is stored at each work terminal WT that has imported them.
Control of tightening and mating operations within the responsible process
Used for In addition, each work terminal WT includes component data,
When importing tightening data and mating data,
In F4, the area in which they are described is stored.
You. The contents stored in these areas are stored by the work terminal WT.
It is referred to when forming work data described later. (2) Inspection unit data file F6 This inspection unit data file F6 contains the SRS assembly line
Work data corresponding to each vehicle put into the car is stored.
You. These work data are stored in the ALC reception file F1.
Each time new AF-ON data is written, the management terminal M
Created by Tn. Figure 5 shows the format of the work data.
To indicate As shown in the figure, the work data is
Related to AF-ON data that is received data
Or N1 parts data, N2 tightening data, N3
The mating data is included. Each of these items is
Secured to record the results of work performed on
And at the time when created by the management terminal MTn
It is blank with no content. In these blanks,
When the vehicle corresponding to this work data passes through each process
Work results (part numbers,
Tightening data and fitting data) are sequentially written. further
The work data is the date of the mid-term inspection,…, the date of the complete inspection,
…, Adjustment judgment date, etc.
It contains items corresponding to the adjustment process. Each of these items
Also, when the vehicle passes through the relevant process,
The taken data is written. Hereinafter, the operation of the manufacturing management system will be described.
I do. §1. System initialization Power on and initialization of each terminal in the SRS assembly line
The production history management system is activated
It is ready to work. Here, the work terminal WT is initialized.
When an operation for the conversion is performed, the work terminal WT
Work table F4 via the file server FSn
Is accessed and the part data and tightening data in the table are
Data or fitting data to which the work terminal WT belongs
Data corresponding to the process is read. After that,
The work terminal WT reads the tightening data or mating data read out.
Control the tightening or mating operation in the process according to the
You. Further, the work terminal WT receives data from the work table.
When reading, the component data of each data, tightening data or
The order in the fitting data is stored. Thereafter, the work terminal W
The part serial number and tightening torque measurement results
Or if the mating condition is sampled,
The write position on the business data is stored at the time of the above readout.
It is determined according to the ranking. That is, the working end of a process
The last WT is the third part data in the work table F4.
If the work terminal WT is a part,
The serial number collected from the server as the third part data
Incorporate in work data. For tightening data and mating data
The same applies to the case. §2. AF-ON data reception When a vehicle enters the SRS assembly line,
AF-ON data, which is the received data
Is transmitted from the computer HST to the communication terminal CTn. Communication end
When receiving the AF-ON data, the end CTn receives the data.
FSn (n)
= 1 to 3), the file server corresponding to the line number
Send AF-ON data to As a result, the received AF
-ON data is received by ALC received by the file server.
Is written to the communication file F1. §3. Work data creation On the other hand, the management terminal MTn sets the
The determination of the presence or absence of new data is constantly repeated.
Then, the management terminal MTn transmits the new AF-ON data
If found, the contents of the AF-ON data and work
The work data (Figure 5) combined with the contents of the cable
Create in the data file F6. §4. Production history management table issued The host computer HST sends this production management system
After transmitting the AF-ON data, throw it on the SRS assembly line.
Issue a production history management table for the vehicles to be entered. this
The manufacturing history management table shows the vehicles to be put into the SRS assembly line.
A bar code indicating the frame number is printed. This ba
The code is also printed on the assembly specifications. Host computer
The manufacturing history management table issued by Data HST
It is thrown. §5. Processing within each work process The vehicle is conveyed by the conveyor and in the SRS assembly line
Are sequentially sent to each process. In each process, vehicles arrive
Each time, the processing described below is performed. First, the vehicle works
When it arrives before the terminal WT, the bar code of the assembly specification
Is scanned by a barcode reader and
Is read. However, the pair
If the attached specification is broken, the manufacturing history management table in the vehicle
Is read. Next, the work terminal WT connects to the barcode reader.
Therefore, using the read frame number as a key,
The work data in the data file F6 is searched. Then check
Based on the search results, the operation data corresponding to the SRS symbol
Read the business table data and configure SRS for the vehicle
It is determined whether the parts to be assembled should be assembled. Here, the arriving vehicle is an SRS specification vehicle.
And that work must be performed in the process.
The frame number read by the barcode reader
The work data corresponding to the number is the inspection unit data file F6
And this work data is stored in the work terminal WT.
The data is written to the work data storage area in the memory. Ma
The contents of the work data are displayed on the screen of the work terminal WT.
Is done. FIG. 6 shows an example of a display screen of the work terminal WT.
Things. Here, the dash sensor-R assembly process
The contents of the work data in the
Part number (dash sensor-R)
The data such as the tightening point for the is displayed. Ma
Also, during the operation, the serial number of the part (
(B)) and tightening work is completed at each tightening point
The data of the tightening value detected at the time (column (b))
Work judgment results (column (c)) for the tightening work
Is displayed. Then, the work assigned to the process
Work is performed. The details are described below for each process.
I do. The main flow of the processing in one process is shown in FIG.
You. (1) Dash sensor-R assembly process and dash sensor
SA-L assembly process The work contents in each of these steps are referred to as dash sensor-R.
The assembling step will be described as an example as follows. When the worker enters the serial number of the dash sensor-R
Read the barcode of the issue with a barcode reader
And whether the reading was successful or not
(Step SP1). Here, "N
In the case of "o", the reading is redone. Also, "Yes"
In this case, the serial number is output to the work terminal WT and the work
The terminal WT performs the process in the work data storage area.
By referring to the corresponding part data area,
What dash sensors should be assembled in the process
Is determined from the same serial number (step
SP2). Here, “Yes” means “passed”
A chime is sounded (step SP3). Also, "N
o "means that the part is not suitable for assembly
And sound a warning buzzer (step SP4). This place
In this case, the worker prepares another part (step SP7), and again
Bar code of the serial number of the part
(Step SP1). In step SP2, "pass" is determined.
If it is determined that the work terminal is in the work data storage area,
Whether serial number data is written in the corresponding location
It is determined whether it is not (step SP5). This judgment result
If "Yes", "Serial number reading is duplicated
It was done. Barco assembly specifications for the current vehicle
Warning that the task of reading the code has been forgotten ''
A buzzer sounds (step SP6). In this case,
Work is interrupted. To resume work, the vehicle
The work of reading the barcode of the assembly specification is required.
On the other hand, when the determination is “No” in step SP5,
The serial number is written in the work data storage area.
In rare cases, the following operation is performed (step SP8). Assembling the dash sensor R to the vehicle body
At the same time, insert a bolt into the specified place, and
Control) tighten the bolts with a wrench and
The sensor R is fixed to the vehicle body. ・ Tighten the above bolts with a constant torque wrench
Confirm. With these operations, tightening torque with ETC wrench
And confirmation of tightening value with constant torque wrench
(Pass / Fail) is measured by each wrench sensor
Then, these measurement results are input to the work terminal WT.
Then, the measurement result of each torque is within a predetermined allowable range.
Is determined, and the determination result is displayed on the work terminal.
In addition, each tightening of the process in the work data storage area
Measurement results of each torque are written in the area corresponding to the work
I will. In each of the above operations, replacement of parts
Is determined by the operator as to whether or not it is necessary (step SP
9). Here, in the case of “Yes”, the
The work terminal stores the current part from the work data storage area.
Delete all the work data related to (Step SP1)
0). Then, the worker prepares another part (step S
P7) Returning to step SP1, the serial number of the part
Read the barcode of the number with a barcode reader
You. If the data is not erased, the
In the SP5, "The serial number has already been read
Is replaced with a warning buzzer.
Cannot be performed. Dash sensor-L assembly process is similar.
Work is performed. (2) SRS unit mounting process a. Attach SRS unit to vehicle and place
Insert the bolt into the bolt and tighten the bolt with the ETC wrench
To fix the SRS unit to the vehicle body. b. Tighten the bolt with a constant torque wrench. In addition to the steps described above, the following steps
Once the necessary SRS parts have been
A fitting inspection is performed as necessary. (3) Sensor & unit mating inspection process (4) Cable reel mating inspection process (5) Module assembly mating inspection process (6) Module assembly tightening process Thus, the work in each process is completed,
The next vehicle arrives in front of the work terminal WT in each process
Then, as in this case, the bar code of the assembly specification is
The document is scanned by the reader (step SP11).
Then, the work terminal WT stores the work data in which the work result is written.
Check the data for this process and
Data is complete and "NG" for each work
(Step SP1)
3). Here, if "Yes", the work data storage area
The work data written in is transmitted (step SP
16) If “No”, the barcode of the next vehicle
Suspends the processing associated with scanning and issues a buzzer warning.
Perform (Step SP14). There is no data input to the work terminal WT.
The predetermined time (3 minutes here, but variable)
Even when the time has elapsed (detected in step SP12),
The process proceeds to step SP13 and determines “Yes”.
The work data in the work data storage area
Is issued (step SP16). This is inside the work terminal
Saved data is not sent forever
This is to avoid stagnation. In step SP14, a buzzer sounds.
In the event that the worker has
Data problems, and should the data be sent?
Or decide to end the work and start over
You. If the same data is to be transmitted, be prepared for the work terminal WT.
When the obtained "flow key" is pressed (step SP15
), Work data in the work data storage area
Is transmitted (step SP16). Meanwhile, finish the work
In this case, the user presses the “end key” (step S
P17). Above, the processing in each step is
finish. As described above, the work terminal WT includes the next vehicle
Until the barcode attached to is read
Vehicle data is left, and work data is transmitted for a predetermined time.
Waiting. In this way, it is necessary to redo work
Work data can be easily changed by the work terminal
is there. In this case, having the warning function as described above
To prevent overwriting of data,
Data can be transmitted reliably. Also, in the work content
Even if there is an “NG” determination point,
Business data or redo work
Can be selected without delaying the work.
Appropriate processing can be performed according to And the vehicle is SRS group
By passing through all the processes required for
Parts data, tightening data and
And the transmission of the mating data is completed.
In the inspection unit data file F6 created by T
Business data. §6. Inspection process Vehicles that have completed the assembly of SRS parts after passing through each process
After that, it is transported to the intermediate inspection process, and the middle inspection terminal in that process
Arrive before MIT. And from the vehicle production history tube
The logical table is taken out and the work in the inspection unit data file F6 is performed.
Matching work data is searched from the
Is displayed. And work
The worker judges whether the SRS assembly work was performed normally or not.
You. If this judgment result is "Yes", the manufacturing history management table
The work data is printed on. In the case of "No", the middle inspection terminal M
IT stores the work data in the inspection unit data file F6.
Information that means "passing" as an item of the middle inspection judgment
Write. And the worker has completed the work normally
A comprehensive determination is made as to whether or not the answer is yes. The result of this judgment is
In the middle inspection judgment item of the work data in the data file F6,
Get in. Then, an intermediate inspection is performed by the management terminal MTn.
The work data of the finished vehicle is read. In addition, other
AF-OFF data with necessary background information is created.
And written to the ALC transmission file F2. And
The AF-OFF data is transmitted from the communication terminal CTn to the host.
Sent to computer HST. Intermediate inspection passed
The vehicle that was turned into the completed vehicle inspection process
Arrives before the complete inspection terminal FIT. And the workers
Check the manufacturing history management table to see if the work was completed successfully
Make a comprehensive judgment. A defect was found as a result of this judgment
In this case, "passed"
Write information that means "stop". Inspection result is intermediate inspection
At the same time, host computer as AF-OFF data
HST is sent to the host computer HST
It is determined whether both can be shipped. [0046] As described above, the production according to the present invention is carried out.
According to the management system, the new assemblyAssembled objectidentification
Or the work result data is
When a predetermined time has elapsed since the data was written to the data holding unit
IfWork result dataIs determinedStorage meansOut to
Is forced. On the other hand, if the content of the data is
EvenStorage meansToWork result dataOutput can be selected
When the work to identify the assembly is performed by the worker
In addition, it is necessary to ensure that identification is performed without delay
The above effect can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing a configuration of a manufacturing management system according to one embodiment of the present invention. FIG. 2 is a diagram showing a relationship between various management files and terminals that handle them in the embodiment. FIG. 3 is a diagram showing a group of devices connected to a work terminal in the embodiment. FIG. 4 is a diagram showing a data format in a management file used in the embodiment. FIG. 5 is a diagram showing a data format in a management file used in the embodiment. FIG. 6 is a diagram showing an example of a display screen of the work terminal in the embodiment. FIG. 7 is a diagram showing a flow of processing in one process in the embodiment. [Description of Signs] 1, 2, bar code reader (identification means), MT1 to MT3, management terminal (management means), WT, work terminal (processing detection means), FS1 to FS3, file server (storage means) ), F4 ... work table, F6 ... inspection machine data file, HST ... host computer.

Claims (1)

(57) [Claims] [Claim 1] Flow through a production line including a plurality of production steps.
Assembly identification means for identifying the assembly to be assembled;
Output the work result applied to the assembly in the manufacturing process
Work control means with assembly detection means for each manufacturing process
And issues a work instruction to the work control means for each of the manufacturing steps.
And the data output from the work control means.
And a storage means for storing the information.
The work control means outputs a work instruction from the storage means and an output from the assembly detection means.
A data holding unit for writing a work result to be input, wherein the work control unit determines that a new assembly is identified by the assembly identification unit.
Or the work result is written to the data holding department.
When a predetermined time has passed since the data was
The contents of the possessed part are matched with the work instructions written in the storage means.
Judge whether or not
Output the contents of the data holding section to the storage means,
If not, a warning is issued by warning means and the memory
A production management system for allowing the user to select whether or not to output to a stage .