JP3882696B2

JP3882696B2 - Production equipment layout method

Info

Publication number: JP3882696B2
Application number: JP2002190367A
Authority: JP
Inventors: 泰明松永
Original assignee: Denso Corp
Current assignee: Denso Corp
Priority date: 2002-06-28
Filing date: 2002-06-28
Publication date: 2007-02-21
Anticipated expiration: 2022-06-28
Also published as: JP2004034162A

Description

【０００１】
【発明の属する技術分野】
本発明は、加工部及び搬送部を備える生産設備を複数備える生産ラインにおける生産設備のレイアウト方法に関する。
【０００２】
【発明が解決しようとする課題】
例えばＡＢＳ装置といった自動車用部品等を、部品の組付けや溶接等の複数の加工工程を経て生産する生産ライン（工場）においては、図３に概略的に示すように、各工程を実行する複数例えば５つの生産設備１〜５が設けられる（加工工程順に第１〜第５の生産設備１〜５とする）。各生産設備１〜５は、作業台上に、部品供給部６や、図示しないワークに対する部品の組付けや溶接等の加工を自動で行う加工部７（ロボットアーム等）を有すると共に、ワークを一方向（この場合図で左から右）に搬送するための搬送部８（便宜上、斜線を付して示す）を有して構成されている。
【０００３】
このとき、一般に、複数の生産設備１〜５は、工程順に並ぶように配置されている（図では左から右に向けて順に並ぶ）。そして、各生産設備１〜５間には、隣合う各搬送部８をつなぐようにして、ワークを一時的に貯留しながら順送りに図で右方に搬送するバッファ搬送部９が設けられるようになっている。このバッファ搬送部９は、１個のワークに対する加工に要する時間が生産設備１〜５毎で異なる場合の調整のためや、あるいは、一部の生産設備１〜５にトラブルが発生して一時的に作業が停止した場合の調整等のために設けられる。尚、前記搬送部８及びバッファ搬送部９は、ベルトやチェーン等のコンベア方式、あるいはグリッパ方式やプッシャ方式等により、この場合図示しないパレット上に載置されたワークを、搬送路上を搬送するように構成されている。
【０００４】
また、図示は省略しているが、図３の例では、ワークの投入部が、第１の生産設備１の図で左側に設けられ、これと共に、パレットを元の位置に回収するため、加工済みのワーク（製品）の排出部も、第１の生産設備１の左側に設けられるようになっている。このため、生産設備１〜５の全体に渡って、ワーク（パレット）を図で右から左に搬送するためのリターン用搬送路１０が設けられると共に、第５の生産設備５の右側には、該第５の生産設備５の搬送部８をリターン用搬送路１０につなげてワークをＵターンさせるようにするリターン部１１が設けられている。
【０００５】
これにて、各生産設備１〜５において、搬送部８に搬入されたワークに対して加工部７による加工を行い、次工程（図で右側）に向けて搬出するといった作業が行われ、１個のワークに関して、第１〜第５の生産設備１〜５で順に加工が行われることにより、製品とされるようになっている。またその作業は、バッファ搬送部９に一時的にワークの貯留が行われながら、多数個のワークに対して連続的に行われるようになっている。尚、生産設備１〜５のなかには（図では第２の生産設備２及び第４の生産設備４）、作業者Ｍによる操作や監視、補助的な作業等を必要とするものもある。
【０００６】
しかしながら、上記したような生産設備１〜５のレイアウト方法では、各生産設備１〜５間にバッファ搬送部９を設けているため、その分生産設備１〜５間のスペースが必要となって、全体の配置面積が大きくなる不具合があった。また、作業者Ｍの作業の合理化を図るために、工程順が離れた生産設備（図３の例では第２の生産設備２と第４の生産設備４）を１箇所（近傍）に集約するといったことが難しかった。この場合、生産設備１〜５を全体としてコ字形やロ字形に配置すれば、作業者Ｍの集約が可能となるが、スペース的にそのような配置が困難となることも考えられる。
【０００７】
本発明は上記事情に鑑みてなされたもので、その目的は、複数の生産設備をつなげて生産ラインを構成する際の配置面積の低減を図ることができる生産設備のレイアウト方法を提供するにある。
【０００８】
【課題を解決するための手段】
本発明の生産設備のレイアウト方法は、ワークに対する複数の加工を順に行う複数の生産設備をレイアウトするにあたり、各生産設備に、ワークの加工が行われるメイン搬送部とワークの貯留が可能なバッファ搬送部とを異なるワーク搬送方向となるように設け、一の生産設備のメイン搬送部が、隣合う他の生産設備のバッファ搬送部につながり、他の生産設備のメイン搬送部が、一の生産設備のバッファ搬送部につながるような組合せを、少なくとも一組設け、この一組の中の一方の生産設備にあっては、前記加工部が前記バッファ搬送部の上方を越えて該メイン搬送部まで延びて加工を行うようにしたところに特徴を有する（請求項１の発明）。
【０００９】
これによれば、生産設備にバッファ搬送部を設けたことによって、生産設備とは別途にバッファ搬送部を設けずとも、ワークの貯留が可能となる。このとき、例えば所定のワーク搬送方向にワークを搬送する際には、一の生産設備でワークの加工が行われ、隣合う他の生産設備はワークの貯留部（あるいは単に通過する部分）として機能する。一方、それとは異なるワーク搬送方向にワークを搬送する際には、それとは逆に、前記他の生産設備でワークの加工が行われ、前記一の生産設備はワークの貯留部（あるいは単に通過する部分）として機能するようになる。
【００１０】
従って、複数の生産設備をつなげて生産ラインを構成する際に、全体として各生産設備におけるワークに対する必要な加工工程を順に実行させることができながら、従来必要であった生産設備間のバッファスペースを不要とする（或いは少なくする）ことができ、全体の配置面積の低減を図ることができる。しかも、各生産設備を一方向に加工工程の順に並べる必要がないので、工程順が離れた生産設備の集約が可能となる。
【００１１】
この場合、より具体的には、各生産設備のメイン搬送部とバッファ搬送部とを、平行で搬送方向が逆方向となるように設け、一の生産設備と隣合う他の生産設備との間では、メイン搬送部及びバッファ搬送部が、位置及び搬送方向が互いに逆となった関係とすることができる（請求項２の発明）。これによれば、一の生産設備と隣合う他の生産設備とを、単純に隣接して並べることによって、一の生産設備のメイン搬送部が、隣合う他の生産設備のバッファ搬送部につながり、他の生産設備のメイン搬送部が、一の生産設備のバッファ搬送部につながるという組合せを容易に構成することができる。
【００１２】
このとき、一方向をワーク搬送方向としたメイン搬送部とそれとは逆方向をワーク搬送方向としたバッファ搬送部とを有する複数の生産設備と、前記逆方向をワーク搬送方向としたメイン搬送部と前記一方向をワーク搬送方向としたバッファ搬送部とを有する複数の生産設備とを、交互に配置し、それら隣合う生産設備間のバッファスペースを省略することができる（請求項３の発明）。
【００１３】
本発明においては、各生産設備の加工部を、両搬送部のどちらに対してもワークに対する加工が可能に構成し、両搬送部のいずれかを選択的にメイン搬送部とすることが可能に構成することもできる（請求項４の発明）。これにより、メイン搬送部とバッファ搬送部とを自在に切替える等の融通性の高いものとなり、レイアウトの変更等を容易に行うことができるようになる。
【００１４】
ところで、上記生産設備においては、加工部のベースから見て手前側にバッファ搬送部が位置され、先方側にメイン搬送部が位置されるケースが生じ、その場合、加工部は、例えば加工アームをバッファ搬送部の上方を越えて先方のメイン搬送部まで延ばして加工を行うことになる。その際、潤滑油等の異物や組付用部品などがバッファ搬送部（貯留されているワーク）上に落下したり、加工アームがワークと干渉してしまう虞が考えられる。そこで、そのようなケースでは、バッファ搬送部に貯留されるワーク部分の上方を覆うカバーを設けるようにすれば（請求項５の発明）、バッファ搬送部に貯留されるワークに上記したような悪影響を及ぼすことを未然に防止することができる。
【００１５】
より具体的な構成として、本発明の請求項６の生産設備のレイアウト方法は、ワークに対して第１〜第５の５つの加工工程を夫々第１〜第５の生産設備により順に実行する場合において、前記第１〜第５の生産設備は、作業台上に、部品供給部や前記ワークに対する部品の組付けや加工を自動で行う加工部を有していると共に、前記作業台の作業者の作業位置に近い側である先端側に、一方向及びそれとは逆方向の両方向に延び夫々前記ワークを搬送する２つの搬送部が設けられており、前記５つの生産設備のうち、第１、第２、第３の生産設備においては、前記加工部のベースから見て手前側の搬送部が、前記一方向をワーク搬送方向とし搬入されたワークに対して該加工部により加工を行うメイン搬送部とされると共に、前記作業位置側の搬送部が、前記逆方向をワーク搬送方向とし搬入されたワークの貯留が可能なバッファ搬送部とされ、前記５つの生産設備のうち、第４、第５の生産設備においては、前記加工部のベースから見て手前側の搬送部が、前記一方向をワーク搬送方向とし搬入されたワークの貯留が可能なバッファ搬送部とされると共に、前記作業位置側の搬送部が、前記逆方向をワーク搬送方向とし搬入されたワークに対して該加工部により加工を行うメイン搬送部とされ、且つ、その加工部が、前記バッファ搬送部の上方を越えて該メイン搬送部まで延びて加工を行うように構成され、前記一方向に並んで、第１の生産設備、第５の生産設備、第２の生産設備、第４の生産設備、第３の生産設備の順に配置され、隣合う生産設備間で、メイン搬送部がバッファ搬送部につながり、バッファ搬送部がメイン搬送部につながる関係とされ、更に、前記第３の生産設備の前記一方向先方側に、該第３の生産設備のメイン搬送部をバッファ搬送部につなげて前記ワークをＵターンさせるリターン部を設けることにより、第１の生産設備のメイン搬送部にて加工部によるワークに対する第１の加工工程が実行され、加工後のワークが、該第１の生産設備のメイン搬送部から第５の生産設備のバッファ搬送部に搬入されて貯留あるいは単なる通過が行われ、引続き、ワークは第２の生産設備のメイン搬送部に搬入されて加工部による第２の加工工程が実行され、加工後のワークは、第２の生産設備のメイン搬送部から第４の生産設備のバッファ搬送部に搬入されて貯留あるいは単なる通過が行われ、次いで、そのワークは第３の生産設備のメイン搬送部に搬入されて加工部による第３の加工工程が実行され、第３の加工工程を経たワークは、第３の生産設備のメイン搬送部からリターン部に送られてＵターンし、搬送方向を逆方向として、第３の生産設備のバッファ搬送部に搬入されて貯留あるいは単なる通過が行われ、引続き、そのワークは第４の生産設備のメイン搬送部に搬入されて加工部による第４の加工工程が実行され、加工後のワークは、第４の生産設備のメイン搬送部から第２の生産設備のバッファ搬送部に搬入されて貯留あるいは単なる通過が行われ、次いで、そのワークは第５の生産設備のメイン搬送部に搬入されて加工部による第５の加工工程が実行され、第５の加工工程を経たワークは、第１の生産設備のバッファ搬送部に送られて排出されるように構成したところに特徴を有する。
このとき、前記生産設備のうち第２の生産設備及び第４の生産設備が、作業者による操作や補助的な作業などを必要とするものであり、それら第２の生産設備及び第４の生産設備を隣接して配置することにより（請求項７の発明）、一人の作業者で済ませることができる。
【００１６】
【発明の実施の形態】
以下、本発明の一実施例について、図１及び図２を参照しながら説明する。図１は、本実施例に係る生産ライン２０における複数の生産設備のレイアウトを示すものである。この実施例の生産ライン２０は、ワーク（図示せず）に対する例えば部品の組付けや溶接等からなる第１〜第５の５つの加工工程を順に経て、製品（例えばＡＢＳ装置等の自動車用部品）を生産するようになっている。
【００１７】
ここで、この生産ライン２０には、第１〜第５の各加工工程を夫々実行するための第１〜第５の５つの生産設備２１〜２５が設置される。これら各生産設備２１〜２５は、この場合、作業台上に、部品供給部２６や、ワークに対する部品の組付けや溶接等の加工を自動で行う加工部２７（ロボットアーム等）を有している。これと共に、各生産設備２１〜２５の作業台の先端側（図で下側）には、図で左右方向（矢印Ａ及び矢印Ｂ方向）に平行に延び、ワークを搬送する２つの搬送部が、次のように設けられている。
【００１８】
即ち、５つの生産設備のうち、前記第１，第２，第３の生産設備２１，２２，２３においては、加工部２７のベースから見て手前側（図で上側）に、矢印Ａ方向（図で右方向）をワーク搬送方向とし搬入されたワークに対して加工部２７により加工が行われるメイン搬送部２８が設けられ、先方側（図で下側）に、そのメイン搬送部２８とは異なる（逆方向となる）矢印Ｂ方向（図で左方）をワーク搬送方向とし搬入されたワークの貯留が可能なバッファ搬送部２９が設けられている。
【００１９】
これに対し、前記第４，第５の生産設備２４，２５においては、加工部２７のベースから見て先方側に、矢印Ｂ方向をワーク搬送方向とし搬入されたワークに対して加工部２７により加工が行われるメイン搬送部３０が設けられ、手前側（図で上側）に、矢印Ａ方向をワーク搬送方向とし搬入されたワークの貯留が可能なバッファ搬送部３１が設けられている。つまり、上記第１〜第３の生産設備２１〜２３と、第４，第５の生産設備２４，２５との間では、メイン搬送部２８，３０及びバッファ搬送部２９，３１が、位置及び搬送方向が互いに逆となった関係に設けられているのである。
【００２０】
また、前記第４，第５の生産設備２４，２５においては、加工部２７が、例えば加工アームをバッファ搬送部３１の上方を越えて先方のメイン搬送部３０まで延ばして加工を行うようになっている。そして、図示はしないが、本実施例では、これら第４，第５の生産設備２４，２５には、バッファ搬送部３１の上部に、ワーク部分の上方を覆う例えばトンネル状のカバーが設けられている。
【００２１】
尚、図１では、メイン搬送部２８，３０とバッファ搬送部２９，３１とを判別しやすくするため、便宜上、メイン搬送部２８，３０側を斜線を付して示している。また、図示及び詳しい説明は省略するが、各搬送部２８〜３１は、ベルトやチェーン等のコンベア方式、あるいはグリッパ方式やプッシャ方式等により、この場合図示しないパレット上に載置されたワークを、搬送路上を順送りに搬送するように構成されている。これら各搬送部２８〜３１は、例えば夫々が独立した駆動機構より駆動（ワークを搬送）するようになっている。さらに、上記生産設備２１〜２５のうち、例えば第２の生産設備２２及び第４の生産設備２４は、作業者Ｍによる操作や監視、補助的な作業等を必要とするものとされている。
【００２２】
さて、本実施例の生産ライン２０においては、上記した各生産設備２１〜２５が図で横（左右）方向に並んで隣接するように配置されるのであるが、ここでは、図で左から右に向けて、第１の生産設備２１、第５の生産設備２５、第２の生産設備２２、第４の生産設備２４、第３の生産設備２３の順に配置されている。また、第３の生産設備２３の右側には、該第３の生産設備２３のメイン搬送部２８をバッファ搬送部２９につなげてワークをＵターンさせるようにするリターン部３２が設けられている。
【００２３】
これにより、例えば、第１の生産設備２１のメイン搬送部２８が第５の生産設備２５のバッファ搬送部３１につながり、第５の生産設備２５のメイン搬送部３０が第１の生産設備２１のバッファ搬送部２９につながるというように、隣合う生産設備２１〜２５間で、一方のメイン搬送部２８，３０が他方のバッファ搬送部２９，３１につながる組合せが、この場合全体的に（交互に逆の関係のものが来るように）設けられているのである。尚、図示はしないが、第１の生産設備２１の図で左側には、そのメイン搬送部２８につながるワークの投入部が設けられると共に、そのバッファ搬送部２９につながる加工済みのワーク（製品）の排出部が設けられている。
【００２４】
次に、上記構成の作用について述べる。図２は、上記生産ライン２０における、１つのワークに関する加工工程（搬送）の手順を示しており、今、加工すべきワークが、投入部から第１の生産設備２１（メイン搬送部２８）に投入されると（Ｐ１）、まず矢印Ａ方向を搬送方向として以下の工程が実行される。
【００２５】
即ち、第１の生産設備２１のメイン搬送部２８にて加工部２７による第１の加工工程が実行される（Ｐ２）。加工後のワークは、メイン搬送部２８から第５の生産設備２５のバッファ搬送部３１に搬入されて貯留（あるいは単なる通過）が行われる（Ｐ３）。引続き、ワークは第２の生産設備２２のメイン搬送部２８に搬入され、加工部２７による第２の加工工程が実行される（Ｐ４）。加工後のワークは、メイン搬送部２８から第４の生産設備２４のバッファ搬送部３１に搬入されて貯留（あるいは単なる通過）が行われる（Ｐ５）。次いで、ワークは第３の生産設備２３のメイン搬送部２８に搬入され、加工部２７による第３の加工工程が実行される（Ｐ６）。
【００２６】
そして、第３の加工工程を経たワークは、第３の生産設備２３のメイン搬送部２８からリターン部３２に送られ（Ｐ７）、そこでＵターンするようにして、今度は矢印Ｂ方向を搬送方向として以下の工程が実行される。即ち、ワークは、リターン部３２から第３の生産設備２３のバッファ搬送部２９に搬入されて貯留（あるいは単なる通過）が行われる（Ｐ８）。引続き、ワークは第４の生産設備２４のメイン搬送部３０に搬入され、加工部２７による第４の加工工程が実行される（Ｐ９）。
【００２７】
加工後のワークは、メイン搬送部３０から第２の生産設備２２のバッファ搬送部２９に搬入されて貯留（あるいは単なる通過）が行われる（Ｐ１０）。次いで、ワークは第５の生産設備２５のメイン搬送部３０に搬入され、加工部２７による第５の加工工程が実行される（Ｐ１１）。第５の加工工程を経たワークは、第１の生産設備２１のバッファ搬送部２９に送られ（Ｐ１２）、そこを通過して排出部に排出されるのである（Ｐ１３）。
【００２８】
これにて、ワークは、メイン搬送部２８，３０及びバッファ搬送部２９，３１を搬送されながら、第１〜第５の生産設備２１〜２５にて第１〜第５の加工工程が順に実行され、製品となって排出されるのである。尚、実際には、ワークは連続的に投入部から生産ライン２０（第１の生産設備２１）に投入され、複数個のワークが連続して順次搬送されながら各生産設備２１〜２５での加工工程が実行されるようになっていることは言うまでもない。
【００２９】
そしてこのとき、一の工程を実行するメイン搬送部２８，３０と、次の工程を実行するメイン搬送部２８，３０との間には、バッファ搬送部２９，３１が設けられていてワークの貯留が可能とされているので、１個のワークに対する加工に要する時間が生産設備２１〜２５間で異なる場合の調整、あるいは、一部の生産設備２１〜２５にトラブルが発生して一時的に作業が停止した場合等に対応することができる。
【００３０】
また、生産設備２１〜２５のうち、第４，第５の生産設備２４，２５においては、加工部２７が、例えば加工アームをバッファ搬送部３１の上方を越えて先方のメイン搬送部３０まで延ばして加工を行うようになっているため、加工部２７から潤滑油等の異物や組付用部品などがバッファ搬送部３１（貯留されているワーク）上に落下したり、加工アームがワークと干渉してしまう虞が考えられるが、本実施例では、バッファ搬送部３１の上部にカバーが設けられているので、ワークに上記したような悪影響を及ぼすことが未然に防止されるのである。
【００３１】
さらには、生産設備２１〜２５のうち第２の生産設備２２及び第４の生産設備２４は、作業者Ｍによる操作や補助的な作業などを必要とするものであるが、ここでは、第２の生産設備２２及び第４の生産設備２４が集約して（隣接して）配置されているので、従来では二人必要となっていた（図３参照）作業者Ｍを一人で済ませることができるようになるのである。
【００３２】
このように本実施例の生産設備２１〜２５のレイアウト方法によれば、複数の生産設備２１〜２５をつなげて生産ライン２０を構成する際に、全体として各生産設備２１〜２５におけるワークに対する必要な加工工程を順に実行させることができながら、従来必要であった生産設備間のバッファスペースを不要とすることができ、全体の配置面積の低減を図ることができるという優れた効果を奏する。しかも、各生産設備２１〜２５を一方向に加工工程の順に並べる必要がないので、工程順が離れた生産設備２１〜２５の集約が可能となるものである。
【００３３】
また、本実施例の生産設備２１〜２５によれば、ワークの搬送方向が互いに逆方向のメイン搬送部２８，３０とバッファ搬送部２９，３１とを設けるようにしたので、生産設備２１〜２５をつなげて生産ライン２０を構成する際に、上記したレイアウト方法を実現するに好適なものとなる。特に本実施例では、第４，第５の生産設備２４，２５のバッファ搬送部３１の上部にカバーを設けるようにしたので、加工部２７が加工アームをバッファ搬送部３１の上方を越えて先方のメイン搬送部３０まで延ばして加工を行うことに伴いバッファ搬送部３１に貯留されているワークに悪影響を及ぼしてしまうことを未然に防止することができるものである。
【００３４】
尚、上記実施例では詳しく説明はしなかったが、本発明に係る生産設備においては、搬送方向の異なる２つの搬送部を設け、加工部を両搬送部ののどちらに対してもワークに対する加工が可能に構成し、両搬送部のいずれかを選択的にメイン搬送部とする（他方がバッファ搬送部となる）ことが可能に構成することもでき、これにより、メイン搬送部とバッファ搬送部とを自在に切替える等の融通性の高いものとなり、レイアウトの変更等を容易に行うことができるメリットを得ることができる。
【００３５】
そして、上記実施例では、矢印Ａ方向をワーク搬送方向としたメイン搬送部２８及び矢印Ｂ方向をワーク搬送方向としたバッファ搬送部２９を有した第１〜第３の生産設備２１〜２３と、矢印Ｂ方向をワーク搬送方向としたメイン搬送部３０及び矢印Ａ方向をワーク搬送方向としたバッファ搬送部３１を有した第４，第５の生産設備２４，２５とを、交互に配置するようにしたが、本発明では、一の生産設備のメイン搬送部が、隣合う他の生産設備のバッファ搬送部につながり、他の生産設備のメイン搬送部が、一の生産設備のバッファ搬送部につながるような組合せを、少なくとも一組設けるようにすれば、それら生産設備間のバッファスペースを不要とすることができ、全体としての配置面積の低減を図ることができる。
【００３６】
さらには、必要に応じて生産設備間に別途のバッファ搬送部を設けても良く、その分貯留可能なワークの数を増やすことができる。
【図面の簡単な説明】
【図１】本発明の一実施例を示すもので、生産ラインにおける複数の生産設備のレイアウトの状態を概略的に示す平面図
【図２】１個のワークに関する加工の工程を示す図
【図３】従来例を示す図１相当図
【符号の説明】
図面中、２０は生産ライン、２１〜２５は生産設備、２７は加工部、２８，３０はメイン搬送部、２９，３１はバッファ搬送部を示す。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to layout how the production equipment in a production line comprising a plurality of production facilities comprising a processing unit and a transport unit.
[0002]
[Problems to be solved by the invention]
For example, in a production line (factory) that produces automobile parts such as ABS devices through a plurality of processing steps such as assembly and welding of parts, a plurality of processes that execute each step are schematically shown in FIG. For example, five production facilities 1 to 5 are provided (first to fifth production facilities 1 to 5 in the order of processing steps). Each of the production facilities 1 to 5 has a component supply unit 6 and a processing unit 7 (robot arm or the like) that automatically performs processing such as assembly and welding of a component to a workpiece (not shown) on the work table. It is configured to have a transport unit 8 (indicated by hatching for convenience) for transporting in one direction (in this case, from left to right in the figure).
[0003]
At this time, generally, the plurality of production facilities 1 to 5 are arranged so as to be arranged in the order of steps (in the figure, they are arranged in order from the left to the right). And between each production equipment 1-5, it connects so that each conveyance part 8 which adjoins may be provided so that the buffer conveyance part 9 which conveys to the right in a figure may be provided to a forward feed while temporarily storing a work. It has become. This buffer transfer unit 9 is used for adjustment when the time required for processing a single workpiece differs for each production facility 1 to 5 or temporarily due to trouble occurring in some production facilities 1 to 5. It is provided for adjustment when work is stopped. The transport unit 8 and the buffer transport unit 9 transport a work placed on a pallet (not shown) on the transport path by a conveyor system such as a belt or a chain, or a gripper system or a pusher system. It is configured.
[0004]
Although not shown, in the example of FIG. 3, the workpiece input unit is provided on the left side in the drawing of the first production facility 1, and together with this, the pallet is recovered to the original position. A discharge part of the finished work (product) is also provided on the left side of the first production facility 1. For this reason, a return conveyance path 10 for conveying a workpiece (pallet) from right to left in the drawing is provided throughout the production facilities 1 to 5, and on the right side of the fifth production facility 5, A return unit 11 is provided for connecting the transfer unit 8 of the fifth production facility 5 to the return transfer path 10 to make the workpiece U-turn.
[0005]
Thus, in each of the production facilities 1 to 5, the work carried out by the machining unit 7 is performed on the workpiece carried into the conveyance unit 8, and the work is carried out toward the next process (right side in the drawing). The individual workpieces are processed in order by the first to fifth production facilities 1 to 5 to be products. Further, the work is continuously performed on a large number of works while the work is temporarily stored in the buffer transport unit 9. Note that some of the production facilities 1 to 5 (the second production facility 2 and the fourth production facility 4 in the figure) require operation and monitoring by the operator M, auxiliary work, and the like.
[0006]
However, in the layout method of the production facilities 1 to 5 as described above, since the buffer transport unit 9 is provided between the production facilities 1 to 5, the space between the production facilities 1 to 5 is required accordingly. There was a problem that the entire layout area was large. Further, in order to rationalize the work of the worker M, the production facilities (the second production facility 2 and the fourth production facility 4 in the example of FIG. 3) that are separated from each other in the order of processes are collected in one place (near). It was difficult. In this case, if the production facilities 1 to 5 are arranged in a U-shape or a B-shape as a whole, the workers M can be aggregated, but such an arrangement may be difficult in terms of space.
[0007]
The present invention has been made in view of the above circumstances, Near its object is to provide a layout method of production facilities can be reduced layout area in constructing production line by connecting a plurality of production facilities The
[0008]
[Means for Solving the Problems]
The production facility layout method according to the present invention includes a main transport section where workpieces are processed and a buffer transport capable of storing the workpieces in each production facility when laying out a plurality of production facilities that sequentially perform a plurality of processes on the workpieces. The main transfer unit of one production facility is connected to the buffer transfer unit of another adjacent production facility, and the main transfer unit of the other production facility is connected to the one production facility. At least one combination is provided so as to connect to the buffer transport section, and in one production facility in the set, the processing section extends over the buffer transport section to the main transport section. Thus, it is characterized in that it is processed (invention of claim 1).
[0009]
According to this, by providing the buffer transfer unit in the production facility, it is possible to store the workpiece without providing the buffer transfer unit separately from the production facility. At this time, for example, when a workpiece is transferred in a predetermined workpiece transfer direction, the workpiece is processed in one production facility, and the other adjacent production facilities function as a workpiece storage unit (or simply a passing portion). To do. On the other hand, when a workpiece is transferred in a different workpiece transfer direction, the workpiece is processed in the other production facility, and the one production facility passes through the workpiece storage unit (or simply passes through). Part).
[0010]
Therefore, when constructing a production line by connecting multiple production facilities, it is possible to sequentially execute the necessary machining steps for workpieces in each production facility as a whole, while reducing the buffer space between production facilities that has been necessary in the past. This can be eliminated (or reduced), and the overall arrangement area can be reduced. Moreover, since it is not necessary to arrange the production facilities in one direction in the order of the processing steps, it is possible to aggregate the production facilities with different order of steps.
[0011]
In this case, more specifically, the main transfer unit and the buffer transfer unit of each production facility are provided in parallel so that the transfer direction is opposite, and between one production facility and another adjacent production facility. Then, the main conveyance part and the buffer conveyance part can be in a relationship in which the positions and the conveyance directions are opposite to each other (invention of claim 2). According to this, the main transfer unit of one production facility is connected to the buffer transfer unit of another adjacent production facility by simply arranging one production facility and another adjacent production facility next to each other. The combination that the main transfer unit of another production facility is connected to the buffer transfer unit of one production facility can be easily configured.
[0012]
At this time, a plurality of production equipment having a main transport unit with one direction as a work transport direction and a buffer transport unit with a reverse direction as the work transport direction, and a main transport unit with the reverse direction as a work transport direction, It is possible to alternately arrange a plurality of production facilities having a buffer conveyance section whose one direction is the workpiece conveyance direction, and to omit a buffer space between the adjacent production facilities (invention of claim 3).
[0013]
In the present invention, the processing unit of each production facility is configured to be capable of processing a workpiece with respect to both of the transfer units, and either of the transfer units can be selectively used as a main transfer unit. It can also be configured (invention of claim 4). As a result, the main conveyance unit and the buffer conveyance unit can be freely switched, and the layout can be easily changed.
[0014]
By the way, in the above production equipment, there is a case in which the buffer transport unit is positioned on the front side as viewed from the base of the processing unit and the main transport unit is positioned on the front side. In this case, the processing unit includes, for example, a processing arm. The processing is performed by extending the upper part of the buffer transport unit to the main transport unit ahead. At that time, there is a possibility that foreign matters such as lubricating oil, assembly parts, etc. may fall on the buffer transfer section (the stored work) or the processing arm may interfere with the work. Therefore, in such a case, if a cover is provided to cover the upper part of the work portion stored in the buffer transport section (the invention of claim 5), the above-described adverse effects on the work stored in the buffer transport section. Can be prevented in advance.
[0015]
As good Ri specific configuration, layout method of production equipment according to claim 6 of the present invention is executed in order by the first to fifth five processing steps respectively first to fifth production facilities with respect to the workpiece In this case, the first to fifth production facilities have a processing unit for automatically assembling and processing a component supply unit and a part on the work on the work table, and the work of the work table. Two transfer sections that extend in one direction and both directions opposite to the one direction are provided on the tip side that is closer to the worker's work position, and the first of the five production facilities. In the second and third production facilities, the transport unit on the near side as viewed from the base of the processing unit performs processing by the processing unit with respect to the workpiece loaded with the one direction as the work transport direction. It is considered as a transfer section and the working position side The transfer unit is a buffer transfer unit capable of storing the workpieces loaded with the reverse direction as the workpiece transfer direction. Of the five production facilities, in the fourth and fifth production facilities, the processing unit The transport section on the near side as viewed from the base is a buffer transport section that can store the work that is loaded with the one direction as the work transport direction, and the transport section on the work position side has the work in the reverse direction. A main transport unit that performs processing by the processing unit on a workpiece that is loaded in the transport direction, and the processing unit extends to the main transport unit over the buffer transport unit so as to perform processing. Are arranged in the above-mentioned one direction, arranged in the order of the first production facility, the fifth production facility, the second production facility, the fourth production facility, the third production facility, and between adjacent production facilities. The main transfer part is It is connected to the transfer unit, and the buffer transfer unit is connected to the main transfer unit. Further, the main transfer unit of the third production facility is connected to the buffer transfer unit on the one-way side of the third production facility. By providing a return portion for turning the workpiece in a U-turn, a first machining step for the workpiece by the machining portion is executed in the main transfer unit of the first production facility, and the workpiece after the machining is performed in the first production From the main transfer unit of the equipment, it is carried into the buffer transfer unit of the fifth production facility and stored or simply passed, and then the workpiece is carried into the main transfer unit of the second production facility and second processed by the processing unit. The machining process is performed, and the workpiece after machining is carried from the main conveyance unit of the second production facility to the buffer conveyance unit of the fourth production facility and stored or simply passed. The workpiece is carried into the main transfer unit of the third production facility, and the third processing step by the processing unit is executed. The workpiece after the third processing step is transferred from the main transfer unit of the third production facility to the return unit. It is sent to make a U-turn, and the transfer direction is reversed, and it is carried into the buffer transfer unit of the third production facility and stored or simply passed, and the work continues to the main transfer unit of the fourth production facility. The fourth processing step by the processing unit is carried in, and the processed workpiece is transferred from the main transfer unit of the fourth production facility to the buffer transfer unit of the second production facility for storage or simple passage. Then, the workpiece is carried into the main transfer unit of the fifth production facility, the fifth processing step by the processing unit is executed, and the workpiece that has undergone the fifth processing step is transferred to the buffer of the first production facility. Sent to the department Characterized in was configured to be discharged.
At this time, among the production facilities, the second production facility and the fourth production facility require an operation or an auxiliary work by an operator, and the second production facility and the fourth production facility. By arranging the facilities adjacent to each other (invention of claim 7 ), it is possible to complete with one worker.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be described below with reference to FIGS. FIG. 1 shows a layout of a plurality of production facilities in the production line 20 according to the present embodiment. The production line 20 of this embodiment is a product (for example, an automotive part such as an ABS device) that passes through five first to fifth processing steps including, for example, assembly of parts or welding to a workpiece (not shown). ).
[0017]
Here, the production line 20 is provided with first to fifth production facilities 21 to 25 for executing the first to fifth processing steps, respectively. In this case, each of these production facilities 21 to 25 has a component supply unit 26 and a processing unit 27 (robot arm or the like) that automatically performs processing such as assembly and welding of components to the workpiece. Yes. At the same time, on the front end side (lower side in the figure) of the work table of each production facility 21 to 25, there are two conveyance units that extend in parallel in the horizontal direction (arrow A and arrow B direction) in the figure and convey the workpiece. Is provided as follows.
[0018]
That is, among the five production facilities, in the first, second, and third production facilities 21, 22, and 23, as viewed from the base of the processing unit 27 (upward in the figure), the arrow A direction ( A main conveyance unit 28 is provided in which a workpiece 27 is processed by a machining unit 27 with respect to a workpiece loaded with the workpiece conveyance direction as the right direction in the drawing, and the main conveyance unit 28 is on the far side (lower side in the drawing). A buffer transport unit 29 is provided that can store a work that has been loaded with a different (reverse direction) arrow B direction (left side in the figure) as the work transport direction.
[0019]
On the other hand, in the fourth and fifth production facilities 24 and 25, the processing unit 27 applies the workpiece carried in the direction of the arrow B in the direction of the workpiece conveying direction, as viewed from the base of the processing unit 27. A main transport unit 30 for processing is provided, and a buffer transport unit 31 is provided on the front side (upper side in the drawing) that can store the work that is loaded with the direction of arrow A as the work transport direction. That is, between the first to third production facilities 21 to 23 and the fourth and fifth production facilities 24 and 25, the main transport units 28 and 30 and the buffer transport units 29 and 31 are positioned and transported. They are provided in a relationship in which the directions are opposite to each other.
[0020]
In the fourth and fifth production facilities 24 and 25, the processing unit 27 performs processing by extending the processing arm over the buffer transport unit 31 to the main transport unit 30 ahead. ing. Although not shown, in the present embodiment, the fourth and fifth production facilities 24 and 25 are provided with a tunnel-shaped cover, for example, covering the upper portion of the work portion above the buffer transport unit 31. Yes.
[0021]
In FIG. 1, for the sake of convenience, the main transport units 28 and 30 are indicated by hatching in order to easily distinguish the main transport units 28 and 30 and the buffer transport units 29 and 31. Although illustration and detailed explanation are omitted, each of the transport units 28 to 31 is configured such that a work placed on a pallet (not shown) in this case by a conveyor method such as a belt or a chain, or a gripper method or a pusher method, It is comprised so that it may convey in order on a conveyance path. Each of the transport units 28 to 31 is driven (transports a workpiece) by an independent drive mechanism, for example. Further, among the production facilities 21 to 25, for example, the second production facility 22 and the fourth production facility 24 require operation and monitoring by the worker M, auxiliary work, and the like.
[0022]
Now, in the production line 20 of the present embodiment, the above-described production facilities 21 to 25 are arranged so as to be adjacent to each other in the horizontal (left-right) direction in the figure, but here, from left to right in the figure. The first production facility 21, the fifth production facility 25, the second production facility 22, the fourth production facility 24, and the third production facility 23 are arranged in this order. A return unit 32 is provided on the right side of the third production facility 23 to connect the main conveyance unit 28 of the third production facility 23 to the buffer conveyance unit 29 so that the workpiece is U-turned.
[0023]
Thereby, for example, the main transport unit 28 of the first production facility 21 is connected to the buffer transport unit 31 of the fifth production facility 25, and the main transport unit 30 of the fifth production facility 25 is connected to the first production facility 21. The combination in which one main transport unit 28, 30 is connected to the other buffer transport unit 29, 31 between the adjacent production facilities 21 to 25, such as being connected to the buffer transport unit 29, is generally (alternately in this case). It is provided so that the reverse relationship will come. Although not shown, on the left side of the drawing of the first production facility 21, a workpiece input unit connected to the main transfer unit 28 is provided, and a processed workpiece (product) connected to the buffer transfer unit 29 is provided. The discharge part is provided.
[0024]
Next, the operation of the above configuration will be described. FIG. 2 shows a procedure of a machining process (conveyance) related to one workpiece in the production line 20, and the workpiece to be machined now is transferred from the input unit to the first production facility 21 (main conveyance unit 28). When loaded (P1), first, the following process is executed with the direction of arrow A as the transport direction.
[0025]
That is, the first processing step by the processing unit 27 is executed in the main transport unit 28 of the first production facility 21 (P2). The processed workpiece is carried from the main conveyance unit 28 into the buffer conveyance unit 31 of the fifth production facility 25 and stored (or simply passed) (P3). Subsequently, the workpiece is carried into the main transfer unit 28 of the second production facility 22, and the second processing step by the processing unit 27 is executed (P4). The processed workpiece is carried from the main conveyance unit 28 into the buffer conveyance unit 31 of the fourth production facility 24 and stored (or simply passed) (P5). Next, the workpiece is carried into the main transfer unit 28 of the third production facility 23, and the third processing step by the processing unit 27 is executed (P6).
[0026]
And the workpiece | work which passed through the 3rd processing process is sent to the return part 32 from the main conveyance part 28 of the 3rd production equipment 23 (P7), and makes a U-turn there, and this time, the arrow B direction is carried direction now. The following steps are executed. That is, the workpiece is carried from the return unit 32 to the buffer conveyance unit 29 of the third production facility 23 and stored (or simply passed) (P8). Subsequently, the workpiece is carried into the main transfer unit 30 of the fourth production facility 24, and the fourth machining step by the machining unit 27 is executed (P9).
[0027]
The processed workpiece is loaded from the main transport unit 30 into the buffer transport unit 29 of the second production facility 22 and stored (or simply passed) (P10). Next, the workpiece is carried into the main transfer unit 30 of the fifth production facility 25, and the fifth processing step by the processing unit 27 is executed (P11). The workpiece that has undergone the fifth machining step is sent to the buffer transport unit 29 of the first production facility 21 (P12), passes there, and is discharged to the discharge unit (P13).
[0028]
As a result, the first to fifth machining steps are sequentially executed in the first to fifth production facilities 21 to 25 while the workpiece is being conveyed through the main conveyance units 28 and 30 and the buffer conveyance units 29 and 31. It is discharged as a product. Actually, the workpieces are continuously input from the input unit to the production line 20 (first production facility 21), and a plurality of workpieces are successively conveyed and processed at each of the production facilities 21 to 25. Needless to say, the process is executed.
[0029]
At this time, buffer transfer units 29 and 31 are provided between the main transfer units 28 and 30 that execute one process and the main transfer units 28 and 30 that execute the next process, so that workpieces can be stored. Adjustment is possible when the time required for machining a single workpiece differs between the production facilities 21 to 25, or a trouble occurs in some of the production facilities 21 to 25 to temporarily work It is possible to cope with the case where is stopped.
[0030]
Of the production facilities 21 to 25, in the fourth and fifth production facilities 24 and 25, the processing unit 27 extends, for example, the processing arm over the buffer transport unit 31 to the main transport unit 30 ahead. Therefore, foreign matters such as lubricating oil and assembly parts fall from the processing section 27 onto the buffer transport section 31 (the stored work), or the processing arm interferes with the work. However, in this embodiment, since the cover is provided on the upper portion of the buffer transport section 31, it is possible to prevent the above-described adverse effects on the work.
[0031]
Furthermore, among the production facilities 21 to 25, the second production facility 22 and the fourth production facility 24 require operations by the worker M, an auxiliary work, and the like. Since the production facility 22 and the fourth production facility 24 are arranged together (adjacent), two workers are required (refer to FIG. 3), and the worker M can be completed alone. It becomes like this.
[0032]
As described above, according to the layout method of the production facilities 21 to 25 according to the present embodiment, when the production line 20 is configured by connecting the plurality of production facilities 21 to 25, it is necessary for the workpieces in the respective production facilities 21 to 25 as a whole. However, it is possible to eliminate the buffer space between the production facilities, which has been conventionally required, and to reduce the entire arrangement area. Moreover, since it is not necessary to arrange the production facilities 21 to 25 in one direction in the order of the processing steps, it is possible to aggregate the production facilities 21 to 25 having a different process order.
[0033]
In addition, according to the production facilities 21 to 25 of the present embodiment, the main conveyance units 28 and 30 and the buffer conveyance units 29 and 31 whose workpiece conveyance directions are opposite to each other are provided. When the production line 20 is configured by connecting the two, the above-described layout method is suitable. In particular, in the present embodiment, since the cover is provided on the upper part of the buffer transport unit 31 of the fourth and fifth production facilities 24 and 25, the processing unit 27 passes the processing arm over the buffer transport unit 31 and moves ahead. It is possible to prevent the workpieces stored in the buffer conveying unit 31 from being adversely affected by extending the main conveying unit 30 to the machining.
[0034]
Although not described in detail in the above embodiment, the production facility according to the present invention is provided with two conveying parts having different conveying directions, and the machining part is processed on the workpiece with respect to both of the conveying parts. Can be configured such that either one of the two transport units can be selectively used as the main transport unit (the other is the buffer transport unit), whereby the main transport unit and the buffer transport unit Therefore, it is possible to obtain a merit that the layout can be easily changed.
[0035]
And in the said Example, the 1st-3rd production equipment 21-23 which has the main conveyance part 28 which made the arrow A direction the work conveyance direction, and the buffer conveyance part 29 which made the arrow B direction the work conveyance direction, The fourth and fifth production facilities 24 and 25 having the main transfer unit 30 with the arrow B direction as the workpiece transfer direction and the buffer transfer unit 31 with the arrow A direction as the workpiece transfer direction are alternately arranged. However, in the present invention, the main transfer unit of one production facility is connected to the buffer transfer unit of another adjacent production facility, and the main transfer unit of another production facility is connected to the buffer transfer unit of one production facility. If at least one such combination is provided, the buffer space between these production facilities can be eliminated, and the overall arrangement area can be reduced.
[0036]
Is Raniwa may be separately provided in the buffer conveyor section between production equipment as required, it is possible to increase the number of that amount storable work.
[Brief description of the drawings]
FIG. 1 is a plan view schematically showing a layout state of a plurality of production facilities in a production line according to an embodiment of the present invention. FIG. 2 is a diagram showing processing steps for one workpiece. 3] Figure corresponding to FIG. 1 showing a conventional example [Explanation of symbols]
In the drawing, 20 is a production line, 21 to 25 are production facilities, 27 is a processing section, 28 and 30 are main transport sections, and 29 and 31 are buffer transport sections.

Claims

A main conveyance in which a machining unit for machining a workpiece and a component supply unit are provided on the side far from the operator's working position, and a workpiece having a predetermined workpiece conveyance direction is processed by the machining unit. A plurality of production equipment provided with a portion close to the work position and a buffer transport unit capable of storing a work carried in and having a work transport direction different from the main transport unit,
This is a method for laying out a plurality of production facilities in a production line that is arranged so as to connect between the conveyance units and that performs a plurality of processes while sequentially conveying the workpieces through the plurality of production facilities. And
A combination in which the main transfer unit of one production facility is connected to the buffer transfer unit of another adjacent production facility, and the main transfer unit of the other production facility is connected to the buffer transfer unit of the one production facility, At least one set is provided, and in one of the production facilities in the set, the processing section extends to the main transport section over the buffer transport section and performs processing. How to lay out production equipment.

The main transfer unit and the buffer transfer unit of the production facility are provided so that the transfer direction is parallel and reverse, and the main transfer unit is between the one production facility and another adjacent production facility. 2. The production facility layout method according to claim 1, wherein the buffer transport section is provided in a relationship in which the position and the transport direction are opposite to each other.

A plurality of production facilities having a main transport unit with one direction as a work transport direction and a buffer transport unit with a reverse direction as the work transport direction, a main transport unit with the reverse direction as a work transport direction, and the one direction The layout of a production facility according to claim 2, wherein a plurality of production facilities having a buffer transport section with a workpiece transport direction as the workpiece transport direction are alternately arranged, and a buffer space between adjacent production facilities is omitted. Method.

In each of the production facilities, the processing unit is configured to be capable of processing a workpiece with respect to both of the transfer units, and can selectively select either of the transfer units as a main transfer unit. 4. The production facility layout method according to claim 1, wherein the production facility layout method is configured.

A production facility that performs processing by extending the processing section over the buffer transport section to the main transport section includes a cover that covers an upper portion of a work portion stored in the buffer transport section. Item 5. A production facility layout method according to any one of Items 1 to 4.

A method of laying out the first to fifth production facilities in a production line that sequentially executes the first to fifth processing steps on the workpiece by the first to fifth production facilities, respectively.
The first to fifth production facilities include a component supply unit and a processing unit that automatically performs assembly and processing of the component with respect to the workpiece on the work table, and work of the operator of the work table. On the tip side, which is the side close to the position, there are provided two transport sections that respectively extend in one direction and the opposite direction to transport the workpiece.
Among the five production facilities, in the first, second, and third production facilities, the transport unit on the near side as viewed from the base of the processing unit is a workpiece that is loaded with the one direction as the work transport direction. On the other hand, it is a main transport unit that performs processing by the processing unit, and the transport unit on the work position side is a buffer transport unit that can store the work that is loaded with the reverse direction as the work transport direction,
Among the five production facilities, in the fourth and fifth production facilities, the transport unit on the near side as viewed from the base of the processing unit can store the workpieces loaded with the one direction as the workpiece transport direction. And a transfer unit on the work position side as a main transfer unit that performs processing by the processing unit with respect to a workpiece loaded with the reverse direction as the workpiece transfer direction. The section extends to the main transport section over the buffer transport section and performs processing,
Arranged in the one direction, the first production facility, the fifth production facility, the second production facility, the fourth production facility, and the third production facility are arranged in this order, and the main transfer is performed between adjacent production facilities. The section is connected to the buffer transport section, the buffer transport section is connected to the main transport section,
Furthermore, by providing a return part for connecting the main transfer part of the third production facility to the buffer transfer part and making the U-turn on the one-way side of the third production facility,
The first processing step for the workpiece by the processing unit is executed in the main transport unit of the first production facility,
The processed workpiece is carried from the main transfer unit of the first production facility to the buffer transfer unit of the fifth production facility and stored or simply passed,
Subsequently, the workpiece is carried into the main transfer unit of the second production facility, and the second machining step by the machining unit is executed.
The processed workpiece is carried from the main transfer unit of the second production facility to the buffer transfer unit of the fourth production facility and stored or simply passed through.
Then, the workpiece is carried into the main transfer unit of the third production facility, and the third processing step by the processing unit is executed,
The workpiece that has undergone the third machining step is sent from the main transfer unit of the third production facility to the return unit, makes a U-turn, and is transferred into the buffer transfer unit of the third production facility with the transfer direction set in the reverse direction. Storage or just passing through,
Subsequently, the workpiece is carried into the main transfer unit of the fourth production facility, and the fourth machining step by the machining unit is executed.
The processed workpiece is carried from the main transfer unit of the fourth production facility to the buffer transfer unit of the second production facility and stored or simply passed through.
Next, the workpiece is carried into the main transport unit of the fifth production facility, and the fifth processing step by the processing unit is executed,
A production facility layout method characterized in that the workpiece that has undergone the fifth machining step is sent to a buffer transfer section of the first production facility and discharged .

Among the production facilities, the second production facility and the fourth production facility require operations by the operator or auxiliary work, and the second production facility and the fourth production facility are adjacent to each other. 7. The production facility layout method according to claim 6, wherein the production facility layout method is arranged as follows .