JP3737351B2 - Production line construction method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to, for example, a production line construction method capable of producing many types of automobiles on a single production line. In particular, the present invention absorbs a deviation in production man-hours due to a difference in models and efficiently produces the production line. The present invention relates to a production line construction method that can be performed.
[0002]
[Prior art]
Conventionally, for example, in a production line that performs a flow operation such as an automobile assembly line, as disclosed in Japanese Patent Application Laid-Open No. 61-21870, a main line for assembling main parts, A sub-line for assembling sub-parts is provided, and a production line using these main lines and sub-lines is constructed.
In addition, in the multi-model mixed production system that produces a large number of models on the same line, as in Japanese Patent No. 2920801, an assembly line tact is appropriately used for mixed production of a plurality of models with different assembly man-hours. What is known to improve production efficiency is known.
[0003]
[Problems to be solved by the invention]
In these conventional production lines, it is necessary to construct the production line based on the model with the largest number of parts, considering the assembly form, equipment, specifications, number of parts, etc., which differ for each model, so the main line is extended. As a result, there is a problem that ancillary facilities and the like increase with surplus man-hours due to fluctuations in man-hours between models, leading to cost increase.
[0004]
That is, in order to assemble vehicles having different numbers of parts on the same line, for example, work man-hours change according to different types of vehicles placed on a conveyor. For this reason, when a model having a small number of parts is transported, the personnel required when a model having a large number of parts is transported are not required, resulting in waste.
Accordingly, the present invention provides a production line construction method capable of efficiently performing production by absorbing a deviation in work man-hours due to a difference in models.
[0005]
[Means for Solving the Problems]
In order to solve the above-mentioned problem, the invention described in claim 1 is a production that can produce many types of products (for example, the vehicle body 2 in the embodiment) on a single main line (for example, the main line 1 in the embodiment). A method for constructing a line, which is input means for inputting part data for each model or a model input to the main line (for example, input means 101 in the embodiment), and part data for each model input by the input means. The control means (for example, the control circuit 100 in the embodiment) for preliminarily storing the procedure for classifying parts of models to be input to the main line, and the display means for displaying the result classified according to the procedure (For example, the display device 102 in the embodiment), a model to be input to the main line is input by the input means, The main parts of the common parts regardless goods-mapped data to a difference in the model (e.g., a main component MB in the embodiment) is extracted as the remaining parts sub-component (e.g., sub-component SB in the embodiment) as The main sub-classification step to be extracted (for example, steps S1 and S2 in the embodiment) and the sub-line (for example, sub-lines 3 to 12 in the embodiment, out of the sub-parts extracted in the main sub-classification step in synchronization with the main line) 14-17, 20-23) sub-parts that can be assembled are extracted as synchronous sub-parts (eg, synchronous sub-part SB1 in the embodiment), and the remaining sub-parts are asynchronous sub-parts (eg, asynchronous sub-parts in the embodiment) Synchronous asynchronous classification process (for example, step in the embodiment) to be extracted as SB2) And 3), all assembling steps of asynchronous sub-component extracted by the synchronous asynchronous classification step, excess workers caused by man-hour difference between the different main components in each model in the main line (e.g., man-hour difference ER2 in the embodiment) Asynchronous sub-parts assignment step (for example, step S6 in the embodiment) assigned to at least one of the surplus workers caused by the man-hour deviation (for example, the man-hour deviation ER1 in the embodiment) between different synchronous sub-parts for each model in the subline ), And processing according to the classification processing procedure .
By configuring in this way, the surplus labor force caused by the man-hour deviation between main parts different for each model in the main line and the man-hour deviation between synchronous parts different for each model in the sub-line is allocated to the assembly work of the asynchronous parts. It becomes possible.
The invention described in claim 2 summarizes the assembly man-hours of the asynchronous sub-components (for example, the length of the asynchronous sub-component SB2 shown in FIG. 8 of the embodiment), reduces the total assembly man-hours (for example, The length of the asynchronous sub-part SB3 in FIG. 8 in the embodiment), and the new assembly man-hours between the surplus worker caused by the man-hour deviation between the main parts and the surplus worker caused by the man-hour deviation between the synchronous sub-parts It is characterized in that it is assigned to at least one of them.
By configuring in this way, the assembly man-hours for asynchronous sub-parts are aggregated, and the new assembly man-hours that reduce the total assembly man-hours are either one of the man-hour deviation between the main parts and the man-hour deviation between the synchronous sub-parts. It becomes possible to assign.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings.
First, the configuration of the production line and the parts to be assembled will be described by taking a production line for assembling a car body as an example. FIG. 1 is an explanatory diagram of a main line of an automobile body assembly line. In FIG. 1, reference numeral 1 denotes a main line, in which various parts are sequentially assembled to a vehicle body (product) 2 of a different model that is painted and conveyed sequentially in the pre-painting process. Specifically, the main line 1 includes a transmission / connection zone ZA, an interior zone ZB, a lower zone ZC, an exterior zone ZD, and a composite guarantee zone ZE. It is transported to the inspection process. Here, a zone guarantee zone ZX described later is provided between the zones ZA, ZB, ZC, ZD, and ZE.
[0007]
In the transmission / line zone ZA, fuel / brake concentration piping, assembly of an air conditioner condenser unit, installation of an ABS modulator assembly, and attachment of a radiator ASSY are performed in order to route the fuel / brake concentration assembly ASSY (assembly). The ASSY subline 3, the air conditioner capacitor unit subline 4, the ABS modulator ASSY subline 5, and the radiator ASSY subline 6 are connected to each other. Each of these sublines is synchronized with the main line 1.
[0008]
In interior zone ZB, installation of roofing unit, installation of fuse unit BOX, installation of air conditioning unit, installation of headlight unit, installation of instrument panel unit ASSY on conveyor, installation of bumper assembly ASSY on conveyor To do this, roofing unit subline 7, fuse unit BOX subline 8, air conditioning unit subline 9, headlight unit subline 10, instrument panel unit assembly conveyor subline 11, and bumper assembly conveyor subline 12 are connected to each other. Yes. Each of these sublines is synchronized with the main line 1. Here, a control BOX sub-subline 13 asynchronous with the main line 1 is connected to the instrument panel unit ASSY conveyor subline 11. In this control box sub-subline 13, all types of control boxes are assembled.
[0009]
In the lower zone ZC, a rear suspension (rear suspension) is assembled on a conveyor, a front suspension (front suspension) is assembled on a conveyor, a fuel tank unit is installed, and an exhaust pipe (exhaust pipe) ASSY is installed. In order to attach a small assembly, a rear suspension subassembly conveyor subline 14, a front suspension ASSY subassembly conveyor subline 15, a fuel tank unit subline 16, and an exhaust assembly subassembly 17 are connected to each other. Each of these sublines is also synchronized with the main line 1.
[0010]
Here, a rear suspension ASSY small assembly sub subline 18 is connected to the rear suspension small assembly conveyor subline 14, and a dress UP engine small assembly subsubline 19 is connected to the front suspension ASSY small assembly conveyor subline 15. The dress-up engine subassembly means that the engine and the mission are assembled.
The rear suspension assembly sub-subline 18 is a line for assembling the rear suspension assembly asynchronously with the main line 1 and supplying the rear suspension assembly sub-subline 14 regardless of the model. The dress UP engine sub assembly sub-subline 19 is a line that performs assembly of the dress UP engine asynchronously with the main line 1 regardless of the model, and supplies the assembly to the front suspension ASSY sub conveyor sub-line 15.
[0011]
And in the exterior zone ZD, in order to attach the front and rear sheets ASSY and the front and rear glasses ASSY, the sheet ASSY sublines 20 and 21 and the glass ASSY sublines 22 and 23 are respectively connected. Each of these sublines is also synchronized with the main line 1.
Finally, in the composite guarantee zone ZE, inspections such as liquid injection work, battery installation, fuel injection, engine start confirmation, etc. are performed.
In the exterior zone ZD, the front door ASSY, the rear door ASSY, and the tailgate ASSY that have been removed in advance in the transmission / passage zone ZA and assembled on the door / tailgate ASSY line 24 are also assembled. In addition to the main line 1, sublines 3 to 12, 14 to 17, 20 to 23, and subsublines 13, 18, and 19, sub sublines (not shown) are provided.
Each of the above zones is divided by function, and the work that has been done for each task in the past is divided by function, and zone guarantee is performed for each function, that is, the zone guarantee zone ZX provided for each zone. Prevents disassembly and reassembly after assembly. For example, in the transmission / communication zone ZA, since both ends of the trunk lid opening / closing cable are attached to predetermined parts and the operation is confirmed in the zone guarantee zone ZX, an assembly failure is detected in the rear zone, and is disassembled and reassembled. This does not happen.
[0013]
Specifically, when assembling for each engagement as in the prior art, for example, when the engagement for attaching the front end of the cable is different from the engagement for attaching the rear end of the cable, the front end of the cable is When the attachment member has been attached without giving a predetermined play to the cable, the assembly failure is not detected until the attachment member attaching the rear end of the cable finds it. Therefore, when a defect is found, in some cases, surrounding parts must be disassembled and reassembled. However, since the zone guarantee is performed for each zone in this way, a defect does not occur later, and the work can be completed for each zone.
[0014]
By the way, different types of vehicle bodies 2 are transported in each zone. For example, if the presence or absence of parts in a certain zone for each model is shown in FIG. 2, the number of parts and assembly man-hours may differ depending on the model. Recognize.
Specifically, in the model D, the part No. 1 to part no. However, in model A, part No. 2. Part No. 4. Part No. 7 does not exist and the model No. 1. Part No. 6. Parts NO. 7 does not exist.
In model C, part No. 1. Part No. 4. Part No. 6 does not exist. 2, NO. 7 does not exist. This is because the number of parts does not match because the equipment is different depending on the model.
[0015]
That is, in this zone, the part No. 3. Part No. 5. Part No. No. 8 is a common part for model A, model B, model C, model D, and model E. 1, NO. 2, NO. 4, NO. 6, NO. 7 is a different part for model A, model B, model C, model D, and model E.
Similarly, in other zones, there are parts that are common to different models and parts that are not common.
Therefore, when a production line is constructed in accordance with a model having a large number of parts, an extra work manpower is required in the assembly work of a model having a small number of parts.
[0016]
Next, a production line construction method will be described with reference to the flowchart shown in FIG. 3 and FIGS.
First, as shown in FIG. 3, in any zone, a common part is extracted as a main part MB regardless of the model (step S1), and the remaining parts are extracted as sub-parts SB (step S2). Step S1 and step S2 constitute a main sub classification process. Specifically, as shown in FIG. 4, the man-hours for each model are represented by a bar graph (the vertical axis is the time as man-hours), and the sub-components SB that are not common to the main components MB common to the models A to E are classified. . In the example shown in FIG. 2, for each model A, B, C, D, E, the part number. 3. Part No. 5. Part No. 8 is extracted as the main part MB, and other part No. 8 is extracted. 1, NO. 2, NO. 4, NO. 6, NO. 7 is extracted as a sub-part SB.
In FIG. 4, what is extracted as the sub-component SB is shown on the sub-side, which is indicated by a chain line. Here, since the main parts MB are different in model even if the parts are common, the man-hours for each model do not match, resulting in variations. A deviation caused by the variation is indicated by hatching in FIG.
[0017]
Next, in step S3 of FIG. 3, out of the sub-parts SB extracted in the main sub-classification step, sub-parts SB that can be assembled in the sub-line in synchronization with the main line 1 are extracted as synchronous sub-parts SB1, and then in step In S4, the remaining subcomponent SB is extracted as an asynchronous subcomponent SB2. Step S3 and step S4 constitute a synchronous asynchronous classification process.
Specifically, as shown in FIG. 5, the man-hours of the sub-parts SB are indicated by bar graphs (the vertical axis is the time as man-hours), and each of the models A to E can be assembled in sub-lines in synchronization with the main line 1. The synchronous subcomponent SB1 and the asynchronous subcomponent SB2 that cannot be synchronized are separated from each other on the boundary line. Here, even if the synchronous sub-component SB1 is shared, the models are different, and therefore the man-hours for each model do not match, resulting in variations. The man-hour deviation ER1 caused by the variation is indicated by hatching. Then, in step S5 of FIG. 3, the asynchronous sub-component SB2 is collected as a new asynchronous sub-component SB3 which is not a model but a single group (asynchronous sub-component collecting step). Specifically, the asynchronous sub-part SB2 (shown in FIG. 5) indicating the lower part from the boundary line is represented by a model so that the man-hour of the sub-part SB in FIG. 6 is indicated by a bar graph (the vertical axis is the time as the man-hour). Each is grouped as a new asynchronous sub-component SB3, which is a single cluster as a whole.
[0018]
Then, in step S6 of FIG. 3, all the assembly steps of all (all models) of the new asynchronous sub-part SB3 extracted in step S3 and step S4 and collected in step S5, that is, the asynchronous sub-part SB2, are aggregated. Allocating the new assembly man-hours with reduced man-hours to the man-hour deviation between main parts MB different for each model in main line 1 and man-hour deviation between synchronous sub-parts SB1 different for each model in sub-line finish. It should be noted that the assembling man-hours of the asynchronous sub-parts SB2 of all models are not so large, and either the man-hour deviation between the main parts MB different for each model in the main line 1 or the man-hour deviation between the synchronous sub-parts SB1 different for each model in the sub-line. If assignment to either one is sufficient, there is no need to assign to both. This step S6 constitutes an asynchronous sub-part assignment process.
Specifically, the total assembly man-hour of the new asynchronous sub-part SB3 in FIG. 6 is a bar graph of the man-hour deviation ER1 between the synchronous sub-parts SB1 of each model indicated by hatching in FIG. 6 and the man-hour of the main part MB in FIG. It is assigned to at least one of the manhour deviation ER2 between the main parts MB of each model indicated by hatching (the vertical axis is the time as the manhour).
[0019]
Here, FIG. 8 shows an asynchronous sub-part SB3 in which the assembly man-hours of the asynchronous sub-component SB2 shown in FIG. 5 are aggregated and the assembly man-hour is reduced as shown in FIG. This shows how the assembly man-hours are assigned to the man-hour deviation ER2 between main parts MB different for each model in the main line 1 and the man-hour deviation ER1 between synchronous sub-parts SB1 different for each model in the sub-line. In FIG. 8, the asynchronous subcomponent SB2 includes the number of man-hours for the asynchronous components of model A to model E in FIG.
Therefore, by integrating the assembly man-hours of the asynchronous sub-component SB2 into the asynchronous sub-component SB3, a production line with higher production efficiency can be constructed. In addition, the man-hours of the asynchronous sub-component SB3 may include dedicated man-hours in addition to the man-hour deviations ER1 and ER2.
[0020]
In the production line thus constructed, surplus produced by the man-hour deviation ER2 between the main parts MB different for each model in the main line 1 and the man-hour deviation ER1 between the synchronous sub-components SB1 different for each model in each sub-line. The labor force can be assigned to the assembly work of the asynchronous sub-part SB2.
[0021]
That is, when the model D having a large number of parts is transported, an operator who is engaged in the work, for example, when the model B having a small number of parts compared to the model D is transported, as shown in FIG. Moreover, in the main line 1, surplus personnel appear when assembling the main part MB, and also in the sub line, surplus personnel appear when assembling the synchronous sub part SB1 as shown in FIG. However, as shown in FIG. 6, these surplus personnel are assembled in a new asynchronous sub-part SB3 that is assembled asynchronously regardless of the model, that is, the asynchronous sub-part SB2 is aggregated to reduce the total assembly man-hours. There is no waste because it is assigned.
[0022]
Specifically, for example, in the lower zone ZC of FIG. 1, when a model with a small number of parts is being transported, the assembly man-hours are small. Therefore, the rear suspension subassembly conveyor subline 14 and the front suspension ASSY subassembly are also provided in the main line 1. Although there are surplus workers in the conveyor subline 15, these surplus workers are allocated to the assembly of the asynchronous subpart SB2 in the rear suspension ASSY subassembly subsubline 18 and the dress up engine subassembly subsubline 19, thereby eliminating waste of labor. Can do.
Therefore, compared to the case where personnel are secured in all zones according to the model D with the largest number of parts, not only can the number of personnel be reduced, but also the load on the workers can be made uniform and the production line can be produced with high efficiency. Can be built. It should be noted that there is a merit of high versatility because it is not affected by changes in the number of models except that the number of extraction steps increases when extracting common parts.
[0023]
As a result, even when the multi-model mixed production method is adopted, the main line can be shortened and the production man-hours due to the difference in the models can be absorbed efficiently. The reduction can be realized and the cost can be greatly reduced.
[0024]
Next, an apparatus for implementing the production line construction method will be described with reference to FIG.
As shown in FIG. 9, in this apparatus, an input means 101 for inputting data to the control circuit 100 is connected to the control circuit 100 for storing the flowchart shown in FIG. The display device 102 for displaying the received data is connected.
[0025]
First, the input means 101 is used to input component data for each model. At the time of this input, the man-hour of the part, the component parts, the zone to be assembled, etc. are input for each model. When this input is completed, the control circuit 100 creates a component map as shown in FIG.
Next, when a model to be input to the main line 1 is selected by the input unit 101, the control circuit 100 extracts a main part (step S1) and a sub part (step S2) according to the flowchart of FIG. ), Extraction of synchronous subparts (step S3), extraction of asynchronous subparts (step S4), extraction of asynchronous subparts (step S4), collection of asynchronous subparts (step S5), allocation of asynchronous subparts (step S6) ) In the order.
The result thus obtained is displayed on the display device 102, and a person who is to be assigned an asynchronous sub-part is selected along the display result.
[0026]
In addition, this invention is not restricted to the said embodiment, For example, it can apply not only to the production line of a motor vehicle but to the production line of various products, such as various electric products.
[0027]
【The invention's effect】
As described above, according to the first aspect of the present invention, the surplus caused by the man-hour deviation between main parts different for each model in the main line or the man-hour deviation between synchronous sub-parts different for each model in the sub-line. Since it is possible to allocate the work force to the assembly work of asynchronous sub-parts, even when producing products of different models, the load on workers should be equalized and a production line with high production efficiency should be built There is an effect that can be.
According to the invention described in claim 2, the assembly man-hours of the asynchronous sub-parts are aggregated, and the new assembly man-hours obtained by reducing the total assembly man-hours are at least the man-hour deviation between the main parts and the man-hour deviation between the synchronous sub-parts. Since it can be assigned to either one, there is an effect that a production line with higher production efficiency can be constructed.
[Brief description of the drawings]
FIG. 1 is an overall view of an automobile body assembly line constructed according to an embodiment of the present invention.
FIG. 2 is an explanatory diagram showing the relationship between parts and models in a certain zone.
FIG. 3 is a flowchart showing a production line construction procedure according to the embodiment of the present invention.
FIG. 4 is a graph showing man-hours for each model in a certain zone.
FIG. 5 is a graph showing the number of sub-parts for each model in a certain zone.
FIG. 6 is a graph showing a state in which asynchronous sub-parts are gathered among sub-parts in a certain zone.
FIG. 7 is a graph showing man-hours for main parts for each model in a certain zone.
FIG. 8 is a graph showing a state in which assembly man-hours for asynchronous sub-parts are aggregated.
FIG. 9 is a schematic configuration diagram of an apparatus for carrying out a production line construction method according to an embodiment of the present invention.
[Explanation of symbols]
1 Main line 2 Body (product)
3-12, 14-17, 20-23 Subline ER1 Effort deviation ER2 Effort deviation MB Main part SB Subpart SB1 Synchronous subpart SB2 Asynchronous subpart SB3 New asynchronous subpart S1, S2 Main subclassification process S3 Synchronous asynchronous classification process S6 Asynchronous sub-part assignment process

Claims (2)

A production line construction method that can produce many types of products on a single main line,
An input means for inputting part data for each model or a model to be input to the main line,
Control means for preliminarily storing a procedure for classifying parts data of models to be input to the main line, and parts data for each model input by the input means is converted into a parts map;
Comprising display means for displaying the results classified according to the procedure,
The model input to the main line is input by the input means, the component mapped data is extracted as a main component regardless of the model, and the remaining components are extracted as sub components. A classification process;
A synchronous asynchronous classification step of extracting sub-components that can be assembled in the sub-line in synchronization with the main line among the sub-components extracted in the main sub-classification step as synchronous sub-components, and extracting the remaining sub-components as asynchronous sub-components; ,
The total assembly man-hours of asynchronous sub-parts extracted in the synchronous asynchronous classification process are the surplus workers caused by the man-hour deviation between main parts that differ for each model in the main line , and the man-hour deviation between synchronous sub-parts that differs for each model in the sub-line A method for constructing a production line, characterized in that processing is performed in accordance with the classification processing procedure comprising an asynchronous sub-part assignment step that is assigned to at least one of surplus workers generated by Aggregate assembly man-hours of the asynchronous sub-component, reduces the total assembling steps and new assembling man-hour, the該新assembling steps, the steps deviation between the excess workers and synchronization sub-component caused by man-hour difference between the main part 2. The production line construction method according to claim 1, wherein the production line is assigned to at least one of the surplus workers generated .

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