JP4207619B2

JP4207619B2 - Assembly production system and assembly production method

Info

Publication number: JP4207619B2
Application number: JP2003084699A
Authority: JP
Inventors: 和彦藤田; 洋小川
Original assignee: Mazda Motor Corp
Current assignee: Mazda Motor Corp
Priority date: 2003-03-26
Filing date: 2003-03-26
Publication date: 2009-01-14
Anticipated expiration: 2023-03-26
Also published as: JP2004291117A

Description

【０００１】
【発明の属する技術分野】
本発明は、組立生産システム及び組立生産方法に関する。
【０００２】
【従来の技術】
組立ラインの作業効率向上のため、各工程における部品の消費具合と部品の要求時刻、部品倉庫内からのスタッカクレーン等による払い出し時間を予測し、その予測に基づいて部品を組立ラインに供給する組立生産システムが知られている（例えば、特許文献１参照）。
【０００３】
【特許文献１】
特開平１０−３１５０７６号公報
【０００４】
【発明が解決しようとする課題】
しかし、上述の組立生産システムでは、短時間停止等が多くライン稼働率が低い組立ラインの場合、予測した部品消費量と実際の消費量に大きな狂いが生じてしまうため、組立作業の待ち時間が発生し作業効率が低下していた。
【０００５】
本発明は、作業者の作業状況に応じて次に必要な部品、治具パレット及びワークを倉庫から搬出入することにより、組立作業の待ち時間を発生させずに作業効率を高める組立生産システム及び組立生産方法を提供することを課題とする。
【０００６】
【課題を解決するための手段】
請求項１に係る発明は、治具パレット上で部品の組付作業を行う第１作業ステーションと、
上記第１作業ステーションで部品が組付けられたワークに対する次工程の作業であるシール剤塗布作業を行うシール剤塗布装置を備えた第２作業ステーションと、
上記治具パレット及び部品を収納する倉庫と、
上記倉庫と上記第１作業ステーションとの間での上記治具パレット及び部品の搬出入、並びに上記倉庫と上記第２作業ステーションとの間での上記治具パレットの搬出入を行う搬送手段と、
上記第１作業ステーションでの作業が終了したときに、上記ワークが載った上記治具パレットを上記倉庫に搬入して、続いて治具パレット及び組み付けるべき部品を該第１作業ステーションに供給し、上記第２作業ステーションでの上記ワークに対する次工程の作業が終了したときに、該ワークが載った治具パレットを上記倉庫に搬入して、続いて上記次工程の作業を行うべきワークが載った治具パレットを該第２作業ステーションに供給するように上記搬送手段の作動を制御する制御手段とを備え、
上記第１作業ステーションは、さらに上記シール剤塗布後のワークに対する部品の組付作業をも行うステーションであり、
上記第２作業ステーションは、さらに上記シール剤塗布後に部品が組み付けられたワークに対するリークテストをも行うステーションであって、リークテスト装置を備え、
上記制御手段は、上記第１作業ステーションに対して、シール剤塗布前まで部品が組み付けられたワークの入れ替わりとしてシール剤塗布後のワークを載せた治具パレット及び該ワークに組み付ける部品を搬入し、上記第２作業ステーションに対して、シール剤塗布後のワークの入れ替わりとしてリークテストを行うべきワークを載せた治具パレットを搬入するように、上記搬送手段の作動を制御することを特徴とする。
【０００７】
従って、本発明によれば、第１作業ステーションでの作業が終了したときに、次工程の作業を行う第２作業ステーションでの作業の終了を待つことなく該ワークを倉庫に搬入して、続いて治具パレット及び組み付けるべき部品を該第１作業ステーションに供給するように該搬送手段の作動を制御する制御手段を備えているから、第１作業ステーションにおいて第２作業ステーションでの作業の遅れ等に影響を受けることなく、すぐに次の組立作業に取りかかることができ、作業の待ち時間が発生せず作業効率がよくなる。
【０００８】
また、上記第２作業ステーションでの作業を、上記ワークに対する次工程の作業を自動で行う自動装置により行うようにすれば、作業者が手作業で行うことが困難な作業を自動装置で行うことができ作業効率がよくなると共に人件費の削減にも有利となる。特に、自動装置としてワークに対してシール剤塗布作業を自動で行うシール剤塗布装置を用いれば、作業者が手作業で行うことが困難で且つ品質にバラツキが生じやすいシール剤塗布作業を自動で行うことができ作業効率がよくなると共に、安定した品質が得られる。
【０００９】
なお、上記シール剤塗布後に部品が組み付けられたワークに対してさらに第２のシール剤塗布を行い、当該第２のシール剤塗布後のワークに対してさらに部品の組付作業を繰り返し行い、当該シール剤塗布と部品組付作業が繰り返されたワークに対してリークテストを行うようにしてもよい。
【００１０】
また、第２作業ステーションが、シール剤塗布後に部品の組み付けられたワークに対するリークテストを行うリークテスト装置を備えているから、作業者が手作業で行うと検査漏れを生じやすいリークテストを自動化することができ、作業効率がよくなると共に検査漏れによる不良品の出荷を防止することができる。
【００１１】
請求項２に係る発明は、請求項１に記載された組立生産システムにおいて、
上記第１作業ステーションは、上記搬送手段により順次供給される部品を収納する複数の部品置場を備えていることを特徴とする。
【００１２】
従って、本発明によれば、上記第１作業ステーションは、複数の部品置場を備えているから、作業者が一方の部品置場から部品の取り出し作業をしている最中でも、上記搬送手段により他方の部品置場に対して部品の供給を行うことができるため待ち時間が発生せず作業効率がよくなると共に、作業者が該搬送手段に衝突することを防止でき作業者の安全確保につながる。
【００１３】
請求項３に係る発明は、請求項１に記載された組立生産システムにおいて、
上記倉庫に対して上記治具パレット及び部品を供給する第２搬送手段を備えていることを特徴とする。
【００１４】
従って、本発明によれば、上記倉庫に対して上記治具パレット及び部品を供給する第２搬送手段を備えているから、該倉庫に治具パレット及び部品を供給する作業を自動で行うことができ、作業効率がよくなると共に人件費の削減に有利となる。
【００１５】
請求項４に係る発明は、治具パレット及び部品を収納する倉庫と、ワークに対する部品の組付を行う第１作業ステーションと、部品が組み付けられたワークに対する次工程の作業であるシール剤塗布作業を行う第２作業ステーションと、上記倉庫と第１及び第２の各作業ステーションとの間での搬送を担う搬送手段とを用いて行う組立生産方法において、
上記倉庫から上記治具パレット及び部品を上記第１作業ステーションに搬出する工程Ａと、
上記第１作業ステーションにおいて上記治具パレット上で部品の組付を行う工程Ｂと、
上記第１作業ステーションから上記部品が組み付けられたワークを上記治具パレットと共に上記倉庫に搬入する工程Ｃと、
上記倉庫から上記次工程の作業を行うべきワークが載った治具パレットを上記第２作業ステーションに搬出する工程Ｄと、
上記第２作業ステーションにおいて上記治具パレット上のワークに対する上記次工程の作業を行う工程Ｅと、
上記第２作業ステーションから上記次工程の作業が終了したワークを上記倉庫に搬入する工程Ｆと、
上記第１作業ステーションにおいてシール剤塗布後のワークに対する部品の組付を行う工程Ｇと、
上記第２作業ステーションにおいてシール剤塗布後に部品が組み付けられたワークに対するリークテストを行う工程Ｈとを備え、
上記工程Ｂが終了したときに、上記搬送手段を制御して上記工程Ｃに続いて上記工程Ａを行い、
上記工程Ｅが終了したときに、上記搬送手段を制御して上記工程Ｆに続いて上記工程Ｄを行い、
上記工程Ｂとして、上記治具パレット上でシール剤塗布前の部品の組付を行い、該工程Ｂが終了したとき、上記工程Ｃに続く工程Ａでは、シール剤塗布後のワークを載せた治具パレット及び該ワークに組み付ける部品を第１作業ステーションに搬入して、当該部品の組付を行い、
上記工程Ｅとして、上記治具パレット上でシール剤の塗布を行い、該工程Ｅが終了したとき、上記工程Ｆに続く工程Ｄでは、リークテストを行うべきワークを載せた治具パレットを第２作業ステーションに搬入して、当該リークテストを行うことを特徴とする。
【００１６】
従って、本発明によれば、第１作業ステーションでの部品組付作業が終了したときに、次工程の作業を行う第２作業ステーションでの作業の終了を待つことなく該部品が組み付けられたワークを倉庫に搬入して、続いて治具パレット及び部品を該第１作業ステーションに供給するように該搬送手段を制御するから、第１作業ステーションにおいて第２作業ステーションでの作業の遅れ等に影響を受けることなく、すぐに次の組立作業に取りかかることができ、作業の待ち時間が発生せず作業効率がよくなる。
【００１７】
なお、上記シール剤塗布後に部品が組み付けられたワークに対してさらに第２のシール剤塗布を行い、当該第２のシール剤塗布後のワークに対してさらに部品の組付作業を繰り返し行い、当該シール剤塗布と部品組付作業が繰り返されたワークに対してリークテストを行うようにしてもよい。
【００１８】
また、上記第２作業ステーションでの作業を、上記ワークに対する次工程の作業を自動で行う自動装置により行うようにすれば、作業者が手作業で行うことが困難な作業を自動装置で行うことができ作業効率がよくなると共に人件費の削減にも有利となる。特に、自動装置としてワークに対してシール剤塗布作業を自動で行うシール剤塗布装置を用いれば、作業者が手作業で行うことが困難で且つ品質にバラツキが生じやすいシール剤塗布作業を自動で行うことができ作業効率がよくなると共に、安定した品質が得られる。
【００１９】
また、第２作業ステーションにリークテスト装置を設け、シール剤塗布後に部品の組み付けられたワークに対するリークテストを行うようにすれば、作業者が手作業で行うと検査漏れを生じやすいリークテストを自動化することができ、作業効率がよくなると共に検査漏れによる不良品の出荷を防止することができる。
【００２０】
請求項５に係る発明は、請求項４に記載された組立生産方法において、
上記第１作業ステーションは、上記搬送手段により順次供給される部品を収納する複数の部品置場を備えていることを特徴とする。
【００２１】
従って、本発明によれば、上記第１作業ステーションは、複数の部品置場を備えているから、作業者が一方の部品置場から部品の取り出し作業をしている最中でも、上記搬送手段により他方の部品置場に対して部品の供給を行うことができるため待ち時間が発生せず作業効率がよくなると共に、作業者が該搬送手段に衝突することを防止でき作業者の安全確保につながる。
【００２２】
【発明の実施の形態】
以下、本発明の実施の形態を図面に基づいて説明する。
【００２３】
＜実施形態＞
図１は、治具パレット１１上で例えば自動車の変速機の部品１２の組付作業を行う第１作業ステーション１と、該第１作業ステーション１で組み立てられた中間製品（ワーク）１３に対する次工程の作業を行う第２作業ステーション２と、該治具パレット１１及び部品１２を収納する倉庫３と、該倉庫３と第１作業ステーション１との間での該治具パレット１１及び部品１２の搬出入、並びに該倉庫３と第２作業ステーション２との間での該治具パレット１１の搬出入を行う搬送手段４と、該搬送手段４の作動を制御する制御手段５と、該倉庫３に治具パレット１１及び部品１２を供給する第２搬送手段６とから形成された組立生産システム１０を示す。ここで、７は作業者を示す。
【００２４】
上記第１作業ステーション１は、上記倉庫３から搬送手段４によって供給される部品１２を収納するために作業者７の左右両側に設けられた部品置場１ａ，１ａと、該搬送手段４によって供給される治具パレット１１を載置して組付作業を行うために該第１作業ステーション１の略中央に設けられた作業台１ｂとを備えている。また、該第１作業ステーション１，１は、隣接して２台設置されており２人の作業者７，７が同時に作業できるようになっている。なお、該第１作業ステーション１は、複数台隣接させて設置してもよいし、１台のみ設置しても構わない。
【００２５】
上記第２作業ステーション２は、上記第１作業ステーション１に隣接して設置されており、上記中間製品１３に対してシール剤塗布作業を行うシール剤塗布装置１５と、該中間製品１３に対する部品１２の組付とシール剤塗布を繰り返して完成された完成製品１４のリークテストを行うリークテスト装置１６と、上記搬送手段４によって上記倉庫３に搬出入される該中間製品１３又は完成製品１４の載った治具パレット１１を載置するための製品台２ａと、該中間製品１３の載った治具パレット１１を該製品台２ａから該シール剤塗布装置１５の作業位置に位置付け、又は完成製品１４の載った治具パレット１１を該製品台２ａから該リークテスト装置１６の作業位置に位置付けるロボットアーム２ｂとを備えている。
【００２６】
上記倉庫３は、上記第１，第２作業ステーション１，２に並設されており、複数に区分けされた倉庫棚３ａ，３ａ，・・・を備えている。また、該倉庫棚３ａ，３ａ，・・・には、治具パレット１１及び部品１２が区分けして収納されている。
【００２７】
上記搬送手段４は、上記倉庫３と第１及び第２作業ステーション１，２との間に配設され、該倉庫３と第１作業ステーション１との間での該治具パレット１１及び部品１２の搬出入、並びに該倉庫３と第２作業ステーション２との間での該治具パレット１１の搬出入を行うものである。
【００２８】
上記制御手段５は、上記倉庫３の倉庫棚３ａ，３ａ，・・・に収納されている治具パレット１１及び部品１２の製品情報、並びに該倉庫棚３ａ，３ａ，・・・の空き情報を管理しており、あらかじめ決められた生産手順に基づいて、該倉庫３と上記第１及び第２の各作業ステーション１，２との間で治具パレット１１及び部品１２の搬出入を行うように上記搬送手段４の作動を制御するものである。
【００２９】
上記第２搬送手段６は、上記倉庫３を挟んで上記搬送手段４と対向して配設され、治具パレット１１及び部品１２を上記倉庫３の空いている倉庫棚３ａ，３ａ，・・・に供給し、又は該倉庫３に搬入された完成製品１４を他工程に搬出するものであり、上記制御手段５によりその作動が制御されている。
【００３０】
以下に、本実施形態における組立生産方法について説明する。
（１）搬送手段４により、倉庫３から治具パレット１１を搬出して第１作業ステーション１の組立台１ｂ上に載置し、次に部品置場１ａ，１ａのうちの一方に部品１２ａを供給する。
（２）上記第１作業ステーション１において、作業者７が治具パレット１１上で部品１２ａの組付作業を行っている間に、次に組み付ける部品１２ｂを部品置場１ａの他方に供給する。そして、上記組付作業を繰り返して、図２及び図３にも示すように、シール剤塗布前の中間製品１３を組み立てる。
（３）作業者７が製品入れ替えボタン（不図示）を押し、上記搬送手段４により該中間製品１３が載った治具パレット１１を上記倉庫３に搬入する。
（４）上記（１）〜（３）の工程を繰り返す。
（５）上記搬送手段４により、上記倉庫３に搬入された中間製品１３が載った治具パレット１１を第２作業ステーション２の製品台２ａ上に載置し、ロボットアーム２ｂにより該中間製品１３が載った治具パレット１１をシール剤塗布装置１５の作業位置に位置付け、該シール剤塗布装置１５により該中間製品１３に対してシール剤１５ａの塗布を行い、第２中間製品１３ａ（図４に図示）を仕上げる。そして、該ロボットアーム２ｂにより、該製品台２ａに該第２中間製品１３ａの載った治具パレット１１を載置する。
（６）第２作業ステーションから作業完了信号が発信され、上記搬送手段４により上記第２中間製品１３ａの載った治具パレット１１を上記倉庫３に搬入する。
（７）上記（５），（６）の工程を繰り返す。
（８）上記搬送手段４により、上記倉庫３に搬入された第２中間製品１３ａが載った治具パレット１１を搬出して第１作業ステーション１の組立台１ｂ上に載置し、次に、部品置場１ａ，１ａのうちの一方に部品１２ｃ（図５に図示）を供給する。
（９）上記第１作業ステーション１において、作業者７が上記第２中間製品１３ａに対して部品１２ｃの組付作業を行っている間に、次に組み付ける部品（不図示）を部品置場１ａ，１ａの他方に供給する。そして、上記組付作業を繰り返してシール剤塗布前の第３中間製品１３ｂ（図５に図示）を組み立てる。
（１０）作業者７が製品入れ替えボタン（不図示）を押し、上記搬送手段４により該第３中間製品１３ｂが載った治具パレット１１を上記倉庫３に搬入する。
（１１）上記（８）〜（１０）の工程を繰り返す。ここで、上記倉庫３に第２中間製品１３ａが搬入されていない場合は、上記（１）〜（３）の工程を繰り返す。
（１２）上記搬送手段４により、上記倉庫３に搬入された第３中間製品１３ｂが載った治具パレット１１を第２作業ステーション２の製品台２ａ上に載置し、ロボットアーム２ｂにより該第３中間製品１３ｂが載った治具パレット１１をシール剤塗布装置１５の作業位置に位置付け、該シール剤塗布装置１５により該第３中間製品１３ｂに対してシール剤１５ａの塗布を行い、第４中間製品１３ｃ（図６に図示）に仕上げる。そして、該ロボットアーム２ｂにより、該製品台２ａに該第４中間製品１３ｃの載った治具パレット１１を載置する。
（１３）第２作業ステーションから作業完了信号が発信され、上記搬送手段４により上記第４中間製品１３ｃの載った治具パレット１１を上記倉庫３に搬入する。
（１４）上記（１２），（１３）の工程を繰り返す。ここで、上記倉庫３に第３中間製品１３ｂが搬入されていない場合は、上記（５），（６）の工程を繰り返す。
（１５）上記搬送手段４により、上記倉庫３に搬入された第４中間製品１３ｃが載った治具パレット１１を搬出して第１作業ステーション１の組立台１ｂ上に載置し、次に、部品置場１ａ，１ａのうちの一方に部品１２ｄ（図７に図示）を供給する。
（１６）上記第１作業ステーション１において、作業者７が上記第２中間製品１３ａに対して部品１２ｄの組付作業を行っている間に、次に組み付ける部品（不図示）を部品置場１ａ，１ａの他方に供給する。そして、上記組立作業を繰り返して完成製品１４（図７に図示）を組み立てる。
（１７）作業者７が製品入れ替えボタン（不図示）を押し、上記搬送手段４により該完成製品１４が載った治具パレット１１を上記倉庫３に搬入する。
（１８）上記（１５）〜（１７）の工程を繰り返す。ここで、上記倉庫３に第４中間製品１３ｃが搬入されていない場合は、上記（１）〜（３）又は上記（８）〜（１０）の工程を繰り返す。
（１９）上記搬送手段４により、上記倉庫３に搬入された完成製品１４が載った治具パレット１１を第２作業ステーション２の製品台２ａ上に載置し、ロボットアーム２ｂにより該完成製品１４が載った治具パレット１１をリークテスト装置１６の作業位置に位置付け、該リークテスト装置１６により該完成製品１４に対してリークテストを行う。そして、該ロボットアーム２ｂにより、該製品台２ａにリークテストの完了した完成製品１４の載った治具パレット１１を載置する。
（２０）第２作業ステーションから作業完了信号が発信され、上記搬送手段４によりリークテストの完了した上記完成製品１４の載った治具パレット１１を上記倉庫３に搬入する。
（２１）上記第２搬送手段６により、上記倉庫３からリークテストの完了した完成製品１４を搬出して他工程に供給する。
【００３１】
以上により、上記（１）〜（２１）の工程を繰り返すことで、作業者７、シール剤塗布装置１５及びリークテスト装置１６の作業待ち時間の発生をなくして、効率のよい組立及び仕上げ作業を行うことができる。
【００３２】
なお、本実施形態では、完成製品１４として自動車の変速機を例にあげたが、本発明はこれに限らず種々の部品の組立に適用できる。
【００３３】
【発明の効果】
請求項１に係る発明によれば、第１作業ステーションでの作業が終了したときに、次工程の作業を行う第２作業ステーションでの作業の終了を待つことなく該ワークを倉庫に搬入して、続いて治具パレット及び組み付けるべき部品を該第１作業ステーションに供給するように該搬送手段の作動を制御する制御手段を備えているから、第１作業ステーションにおいて第２作業ステーションでの作業の遅れ等に影響を受けることなく、すぐに次の組立作業に取りかかることができ、作業の待ち時間が発生せず作業効率がよくなる。
【００３４】
また、上記第２作業ステーションでの作業を、上記ワークに対する次工程の作業を自動で行う自動装置により行うようにすれば、作業者が手作業で行うことが困難な作業を自動装置で行うことができ作業効率がよくなると共に人件費の削減にも有利となる。特に、自動装置としてワークに対してシール剤塗布作業を自動で行うシール剤塗布装置を用いれば、作業者が手作業で行うことが困難で且つ品質にバラツキが生じやすいシール剤塗布作業を自動で行うことができ作業効率がよくなると共に、安定した品質が得られる。
【００３５】
さらに、第２作業ステーションが、シール剤塗布後に部品の組み付けられたワークに対するリークテストを行うリークテスト装置を備えているから、作業者が手作業で行うと検査漏れを生じやすいリークテストを自動化することができ、作業効率がよくなると共に検査漏れによる不良品の出荷を防止することができる。
【００３６】
請求項２に係る発明によれば、請求項１に記載された組立生産システムにおいて、上記第１作業ステーションは、複数の部品置場を備えているから、作業者が一方の部品置場から部品の取り出し作業をしている最中でも、上記搬送手段により他方の部品置場に対して部品の供給を行うことができるため待ち時間が発生せず作業効率がよくなると共に、作業者が該搬送手段に衝突することを防止でき作業者の安全確保につながる。
【００３７】
請求項３に係る発明によれば、請求項１に記載された組立生産システムにおいて、上記倉庫に対して上記治具パレット及び部品を供給する第２搬送手段を備えているから、該倉庫に治具パレット及び部品を供給する作業を自動で行うことができ、作業効率がよくなると共に人件費の削減に有利となる。
【００３８】
請求項４に係る発明によれば、第１作業ステーションでの部品組付作業が終了したときに、次工程の作業を行う第２作業ステーションでの作業の終了を待つことなく該部品が組み付けられたワークを倉庫に搬入して、続いて治具パレット及び部品を該第１作業ステーションに供給するように該搬送手段を制御するから、第１作業ステーションにおいて第２作業ステーションでの作業の遅れ等に影響を受けることなく、すぐに次の組立作業に取りかかることができ、作業の待ち時間が発生せず作業効率がよくなる。
【００３９】
また、上記第２作業ステーションでの作業を、上記ワークに対する次工程の作業を自動で行う自動装置により行うようにすれば、作業者が手作業で行うことが困難な作業を自動装置で行うことができ作業効率がよくなると共に人件費の削減にも有利となる。特に、自動装置としてワークに対してシール剤塗布作業を自動で行うシール剤塗布装置を用いれば、作業者が手作業で行うことが困難で且つ品質にバラツキが生じやすいシール剤塗布作業を自動で行うことができ作業効率がよくなると共に、安定した品質が得られる。
【００４０】
さらに、シール剤塗布後に部品の組み付けられたワークに対するリークテストを自動で行うから、作業者が手作業で行うと検査漏れを生じやすいリークテストを自動化することができ、作業効率がよくなると共に検査漏れによる不良品の出荷を防止することができる。
【００４１】
請求項５に係る発明によれば、請求項４に記載された組立生産方法であって、上記第１作業ステーションは、複数の部品置場を備えているから、作業者が一方の部品置場から部品の取り出し作業をしている最中でも、上記搬送手段により他方の部品置場に対して部品の供給を行うことができるため待ち時間が発生せず作業効率がよくなると共に、作業者が該搬送手段に衝突することを防止でき作業者の安全確保につながる。
【図面の簡単な説明】
【図１】本実施形態に係る組立生産システムの平面概略図。
【図２】本実施形態に係る治具パレット及び部品の組付作業を示す斜視図。
【図３】本実施形態に係る中間製品を示す斜視図。
【図４】本実施形態に係る第２中間製品を示す斜視図。
【図５】本実施形態に係る第３中間製品を示す斜視図。
【図６】本実施形態に係る第４中間製品を示す斜視図。
【図７】本実施形態に係る完成製品を示す斜視図。
【符号の説明】
１第１作業ステーション
２第２作業ステーション
３倉庫
４搬送手段
５制御手段
６第２搬送手段
７作業者
１０組立生産システム
１１治具パレット
１２部品
１３中間製品
１３ａ第２中間製品
１３ｂ第３中間製品
１３ｃ第４中間製品
１４完成製品
１５シール剤塗布装置
１６リークテスト装置[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an assembly production system and an assembly production method.
[0002]
[Prior art]
To improve the work efficiency of the assembly line, predict the consumption of parts in each process, the required time of parts, the payout time by a stacker crane from the parts warehouse, and supply parts to the assembly line based on the predictions A production system is known (see, for example, Patent Document 1).
[0003]
[Patent Document 1]
Japanese Patent Laid-Open No. 10-315076
[Problems to be solved by the invention]
However, in the assembly production system described above, in the case of an assembly line that has many short-time stops or the like and a low line operation rate, a large deviation occurs between the predicted parts consumption and the actual consumption. The work efficiency was reduced.
[0005]
The present invention relates to an assembly production system that improves work efficiency without causing waiting time for assembly work by carrying in / out the necessary parts, jig pallet, and work from the warehouse in accordance with the work situation of the worker, and It is an object to provide an assembly production method.
[0006]
[Means for Solving the Problems]
The invention according to claim 1 is a first work station for assembling parts on a jig pallet;
A second work station provided with a sealant application device for performing a sealant application work that is a work of the next process on a work assembled with parts in the first work station;
A warehouse for storing the jig pallet and parts;
Conveying means for carrying in and out the jig pallet and parts between the warehouse and the first work station, and carrying in and out the jig pallet between the warehouse and the second work station;
When the work at the first work station is completed, the jig pallet carrying the work is carried into the warehouse, and then the jig pallet and the parts to be assembled are supplied to the first work station, When the next process work on the work at the second work station is completed, the jig pallet on which the work is placed is loaded into the warehouse, and then the work to be worked on the next process is loaded. Control means for controlling the operation of the conveying means so as to supply a jig pallet to the second work station ,
The first work station is a station that also performs assembly work of parts to the work after application of the sealant,
The second work station is a station that also performs a leak test on a workpiece in which parts are assembled after application of the sealant, and includes a leak test device,
The control means carries the jig pallet on which the workpiece after application of the sealant is placed and the parts to be assembled to the workpiece as a replacement of the workpiece on which the parts are assembled before application of the sealant to the first work station, The operation of the transfer means is controlled so that a jig pallet carrying a work to be subjected to a leak test is carried into the second work station as replacement of the work after applying the sealant .
[0007]
Therefore, according to the present invention, when the work at the first work station is completed, the work is carried into the warehouse without waiting for the work at the second work station to perform the work of the next process. And a control means for controlling the operation of the conveying means so as to supply the jig pallet and the parts to be assembled to the first work station, the work delay at the second work station in the first work station, etc. It is possible to immediately start the next assembling work without being affected by the above, and the work efficiency is improved without waiting for the work.
[0008]
Further, if the work at the second work station is performed by an automatic device that automatically performs the next process work on the work, the work that is difficult for the operator to perform manually is performed by the automatic device. Work efficiency is improved and labor costs are reduced. In particular, if a sealing agent application device that automatically applies a sealing agent to a workpiece is used as an automatic device, the sealing agent application operation that is difficult for an operator to perform manually and is likely to cause quality variations is automatically performed. As a result, work efficiency is improved and stable quality is obtained.
[0009]
In addition, the second sealant is further applied to the work on which the parts are assembled after the sealant is applied, and the parts are further assembled on the work after the second sealant is applied. You may make it perform a leak test with respect to the workpiece | work in which sealing agent application | coating and parts assembly work were repeated.
[0010]
In addition, since the second work station is equipped with a leak test device for performing a leak test on a workpiece in which a part is assembled after applying the sealant, a leak test that is likely to cause an inspection leak when performed manually by an operator is automated. It is possible to improve work efficiency and prevent shipment of defective products due to inspection omissions.
[0011]
The invention according to claim 2 is the assembly production system according to claim 1,
The first work station is provided with a plurality of parts storage places for storing parts sequentially supplied by the transport means.
[0012]
Therefore, according to the present invention, the first work station is provided with a plurality of parts storage areas, so that while the worker is taking out parts from one of the parts storage areas, the other means is used by the transport means. Since parts can be supplied to the parts place, there is no waiting time, work efficiency is improved, and the worker can be prevented from colliding with the transfer means, thereby ensuring the safety of the worker.
[0013]
The invention according to claim 3 is the assembly production system according to claim 1,
A second conveying means for supplying the jig pallet and parts to the warehouse is provided.
[0014]
Therefore, according to the present invention, since the second transport means for supplying the jig pallet and the parts to the warehouse is provided, the operation of supplying the jig pallet and the parts to the warehouse can be automatically performed. This improves work efficiency and is advantageous for reducing labor costs.
[0015]
The invention according to claim 4 is a warehouse for storing the jig pallet and the parts, a first work station for assembling the parts to the work , and a sealant application work which is a next process work for the work with the parts assembled. In the assembly production method performed using the second work station for carrying out, and the transport means responsible for transport between the warehouse and each of the first and second work stations,
Step A for carrying out the jig pallet and parts from the warehouse to the first work station;
Step B for assembling parts on the jig pallet at the first work station;
A step C of carrying the work assembled with the parts from the first work station into the warehouse together with the jig pallet;
A process D for carrying out a jig pallet carrying a work to be performed in the next process from the warehouse to the second work station;
Step E for performing the next step work on the workpiece on the jig pallet at the second work station;
A process F for carrying the work, which has been completed in the next process from the second work station, into the warehouse ;
A process G for assembling parts to the workpiece after applying the sealant at the first work station;
Including a step H of performing a leak test on a workpiece in which parts are assembled after applying the sealant at the second work station ,
When the process B is completed, the conveying means is controlled to perform the process A following the process C,
When Step E above is finished, we have row the step D following the above step F by controlling the conveying means,
As the process B, the parts before applying the sealant are assembled on the jig pallet, and when the process B is completed, the process A following the process C is a process where the work after applying the sealant is placed. Carrying the tool pallet and the parts to be assembled to the workpiece into the first work station, assembling the parts,
As the process E, a sealant is applied on the jig pallet, and when the process E is completed, in the process D following the process F, a jig pallet on which a workpiece to be subjected to a leak test is placed is second. It is carried into the work station and the leak test is performed .
[0016]
Therefore, according to the present invention, when the part assembling work at the first work station is finished, the work in which the parts are assembled without waiting for the work at the second work station to perform the work of the next process. Is transferred to the warehouse, and then the transfer means is controlled so as to supply the jig pallet and the parts to the first work station, which affects the work delay at the second work station in the first work station. The next assembly work can be started immediately without receiving the work, and the work efficiency is improved without waiting for the work.
[0017]
In addition, the second sealant is further applied to the work on which the parts are assembled after the sealant is applied, and the parts are further assembled on the work after the second sealant is applied. You may make it perform a leak test with respect to the workpiece | work in which sealing agent application | coating and parts assembly work were repeated.
[0018]
Further, if the work at the second work station is performed by an automatic device that automatically performs the next process work on the work, the work that is difficult for the operator to perform manually is performed by the automatic device. Work efficiency is improved and labor costs are reduced. In particular, if a sealing agent application device that automatically applies a sealing agent to a workpiece is used as an automatic device, the sealing agent application operation that is difficult for an operator to perform manually and is likely to cause quality variations is automatically performed. As a result, work efficiency is improved and stable quality is obtained.
[0019]
In addition, if a leak test device is installed at the second work station and a leak test is performed on the workpiece with parts attached after applying the sealant, a leak test that is likely to cause an inspection leak when performed manually by an operator is automated. It is possible to improve the work efficiency and prevent shipment of defective products due to omission of inspection.
[0020]
The invention according to claim 5 is the assembly production method according to claim 4 ,
The first work station is provided with a plurality of parts storage places for storing parts sequentially supplied by the transport means.
[0021]
Therefore, according to the present invention, the first work station is provided with a plurality of parts storage areas, so that while the worker is taking out parts from one of the parts storage areas, the other means is used by the transport means. Since parts can be supplied to the parts place, there is no waiting time, work efficiency is improved, and the worker can be prevented from colliding with the transfer means, thereby ensuring the safety of the worker.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0023]
<Embodiment>
FIG. 1 shows a first work station 1 for performing assembling work of, for example, an automobile transmission part 12 on a jig pallet 11, and a next process for an intermediate product (work) 13 assembled at the first work station 1. The second work station 2 for performing the above work, the warehouse 3 for storing the jig pallet 11 and the parts 12, and the unloading of the jig pallet 11 and the parts 12 between the warehouse 3 and the first work station 1 A transfer means 4 for carrying in and out of the jig pallet 11 between the warehouse 3 and the second work station 2; a control means 5 for controlling the operation of the transfer means 4; The assembly production system 10 formed from the jig | tool pallet 11 and the 2nd conveyance means 6 which supplies the components 12 is shown. Here, 7 indicates an operator.
[0024]
The first work station 1 is supplied by the parts storage 1a, 1a provided on the left and right sides of the operator 7 for storing the parts 12 supplied from the warehouse 3 by the transfer means 4 and the transfer means 4. And a workbench 1b provided substantially at the center of the first work station 1 for mounting the jig pallet 11 to be assembled. The two first work stations 1 and 1 are installed adjacent to each other so that two workers 7 and 7 can work simultaneously. Note that a plurality of the first work stations 1 may be installed adjacent to each other, or only one may be installed.
[0025]
The second work station 2 is installed adjacent to the first work station 1, and includes a sealant application device 15 that performs a sealant application operation on the intermediate product 13, and a component 12 for the intermediate product 13. A leak test device 16 for performing a leak test of the finished product 14 completed by repeating the assembly and sealing agent application, and the intermediate product 13 or the finished product 14 carried in and out of the warehouse 3 by the transport means 4 The product base 2a for placing the jig pallet 11 and the jig pallet 11 on which the intermediate product 13 is placed are positioned from the product base 2a to the working position of the sealant coating device 15, or the finished product 14 A robot arm 2b for positioning the mounted jig pallet 11 from the product base 2a to the working position of the leak test apparatus 16 is provided.
[0026]
The warehouse 3 is provided in parallel with the first and second work stations 1 and 2 and includes warehouse shelves 3a, 3a,. Further, the jig shelves 11 and the parts 12 are separately stored in the warehouse shelves 3a, 3a,.
[0027]
The conveying means 4 is disposed between the warehouse 3 and the first and second work stations 1 and 2, and the jig pallet 11 and the parts 12 between the warehouse 3 and the first work station 1. , And the jig pallet 11 is carried in and out between the warehouse 3 and the second work station 2.
[0028]
The control means 5 displays the product information of the jig pallet 11 and the parts 12 stored in the warehouse shelves 3a, 3a,... Of the warehouse 3, and the availability information of the warehouse shelves 3a, 3a,. The jig pallet 11 and the parts 12 are carried in and out between the warehouse 3 and the first and second work stations 1 and 2 based on a production procedure determined in advance. The operation of the conveying means 4 is controlled.
[0029]
The second transport means 6 is disposed opposite the transport means 4 with the warehouse 3 in between, and the jig pallet 11 and the parts 12 are stored in the warehouse shelves 3a, 3a,. Or the finished product 14 carried into the warehouse 3 is carried out to another process, and its operation is controlled by the control means 5.
[0030]
Below, the assembly production method in this embodiment is demonstrated.
(1) The jig pallet 11 is unloaded from the warehouse 3 by the conveying means 4 and placed on the assembly table 1b of the first work station 1, and then the component 12a is supplied to one of the component locations 1a and 1a. To do.
(2) In the first work station 1, while the worker 7 is performing the work of assembling the part 12 a on the jig pallet 11, the part 12 b to be assembled next is supplied to the other part of the part place 1 a. And the said assembly | attachment operation | work is repeated and the intermediate product 13 before sealing agent application | coating is assembled as shown also in FIG.2 and FIG.3.
(3) The operator 7 presses a product replacement button (not shown), and the jig pallet 11 on which the intermediate product 13 is placed is carried into the warehouse 3 by the transport means 4.
(4) The steps (1) to (3) are repeated.
(5) The jig pallet 11 on which the intermediate product 13 carried into the warehouse 3 is placed is placed on the product stage 2a of the second work station 2 by the transport means 4, and the intermediate product 13 is placed by the robot arm 2b. Is placed at the working position of the sealant application device 15, and the sealant application device 15 applies the sealant 15a to the intermediate product 13, and the second intermediate product 13a (see FIG. 4). Finish (shown). Then, the jig arm 11 on which the second intermediate product 13a is placed is placed on the product base 2a by the robot arm 2b.
(6) A work completion signal is sent from the second work station, and the jig pallet 11 on which the second intermediate product 13a is placed is carried into the warehouse 3 by the transport means 4.
(7) The above steps (5) and (6) are repeated.
(8) The jig pallet 11 on which the second intermediate product 13a carried into the warehouse 3 is loaded by the transport means 4 and placed on the assembly table 1b of the first work station 1, A component 12c (shown in FIG. 5) is supplied to one of the component storage locations 1a and 1a.
(9) In the first work station 1, while the worker 7 is assembling the part 12c to the second intermediate product 13a, a part (not shown) to be assembled next is placed in the part place 1a, Supply to the other of la. Then, the assembly process is repeated to assemble the third intermediate product 13b (shown in FIG. 5) before applying the sealant.
(10) The operator 7 pushes a product replacement button (not shown), and the jig pallet 11 on which the third intermediate product 13b is placed is carried into the warehouse 3 by the transport means 4.
(11) The steps (8) to (10) are repeated. Here, when the 2nd intermediate product 13a is not carried in to the said warehouse 3, the process of said (1)-(3) is repeated.
(12) The jig pallet 11 on which the third intermediate product 13b carried into the warehouse 3 is placed is placed on the product stage 2a of the second work station 2 by the transport means 4, and the robot arm 2b The jig pallet 11 on which the third intermediate product 13b is placed is positioned at the working position of the sealant application device 15, and the sealant application device 15 applies the sealant 15a to the third intermediate product 13b. Finish the product 13c (shown in FIG. 6). Then, the jig arm 11 on which the fourth intermediate product 13c is placed is placed on the product base 2a by the robot arm 2b.
(13) A work completion signal is transmitted from the second work station, and the jig pallet 11 on which the fourth intermediate product 13c is loaded is carried into the warehouse 3 by the transfer means 4.
(14) The above steps (12) and (13) are repeated. Here, when the third intermediate product 13b is not carried into the warehouse 3, the steps (5) and (6) are repeated.
(15) The conveying means 4 unloads the jig pallet 11 on which the fourth intermediate product 13c carried into the warehouse 3 is placed and places it on the assembly table 1b of the first work station 1, A part 12d (shown in FIG. 7) is supplied to one of the parts storage 1a and 1a.
(16) In the first work station 1, while the worker 7 is assembling the part 12d to the second intermediate product 13a, a part (not shown) to be assembled next is placed in the part place 1a, Supply to the other of la. Then, the finished product 14 (shown in FIG. 7) is assembled by repeating the above assembling work.
(17) The operator 7 presses a product replacement button (not shown), and the jig pallet 11 on which the finished product 14 is placed is carried into the warehouse 3 by the transport means 4.
(18) The steps (15) to (17) are repeated. Here, when the 4th intermediate product 13c is not carried in to the said warehouse 3, the process of said (1)-(3) or said (8)-(10) is repeated.
(19) The jig pallet 11 on which the finished product 14 carried into the warehouse 3 is placed is placed on the product stage 2a of the second work station 2 by the transfer means 4, and the finished product 14 is placed by the robot arm 2b. Is placed at the working position of the leak test device 16, and the leak test device 16 performs a leak test on the finished product 14. Then, the jig arm 11 on which the finished product 14 on which the leak test has been completed is placed on the product base 2a by the robot arm 2b.
(20) A work completion signal is transmitted from the second work station, and the jig pallet 11 on which the finished product 14 on which the leak test has been completed is carried by the transport means 4 is carried into the warehouse 3.
(21) The finished product 14 that has been subjected to the leak test is carried out from the warehouse 3 by the second transport means 6 and supplied to another process.
[0031]
As described above, by repeating the steps (1) to (21), it is possible to eliminate the work waiting time of the worker 7, the sealant coating device 15, and the leak test device 16, and to perform efficient assembly and finishing operations. It can be carried out.
[0032]
In the present embodiment, the transmission of an automobile is taken as an example of the finished product 14, but the present invention is not limited to this and can be applied to the assembly of various parts.
[0033]
【The invention's effect】
According to the first aspect of the present invention, when the work at the first work station is completed, the work is brought into the warehouse without waiting for the work at the second work station to perform the work of the next process. Subsequently, since the control means for controlling the operation of the conveying means is provided so as to supply the jig pallet and the parts to be assembled to the first work station, the work at the second work station is performed at the first work station. Without being affected by the delay or the like, the next assembly work can be started immediately, and the work efficiency is improved without any work waiting time.
[0034]
Further, if the work at the second work station is performed by an automatic device that automatically performs the next process work on the work, the work that is difficult for the operator to perform manually is performed by the automatic device. Work efficiency is improved and labor costs are reduced. In particular, if a sealing agent application device that automatically applies a sealing agent to a workpiece is used as an automatic device, the sealing agent application operation that is difficult for an operator to perform manually and is likely to cause quality variations is automatically performed. As a result, work efficiency is improved and stable quality is obtained.
[0035]
Furthermore, since the second work station is equipped with a leak test device for performing a leak test on a workpiece on which a part has been assembled after applying a sealant, the leak test, which is likely to cause an inspection leak when performed manually by an operator, is automated. It is possible to improve work efficiency and prevent shipment of defective products due to inspection omissions.
[0036]
According to a second aspect of the present invention, in the assembly production system according to the first aspect, since the first work station includes a plurality of parts places, the operator takes out parts from one part place. Even while working, parts can be supplied to the other parts storage by the transport means, so there is no waiting time and work efficiency is improved, and the operator collides with the transport means. Can be prevented and the safety of workers can be ensured.
[0037]
According to the invention of claim 3 , the assembly production system according to claim 1 is provided with the second conveying means for supplying the jig pallet and the parts to the warehouse. The operation of supplying the tool pallet and the parts can be automatically performed, and the work efficiency is improved and the labor cost is reduced.
[0038]
According to the invention of claim 4, when the parts assembling work at the first work station is finished, the parts are assembled without waiting for the work at the second work station to perform the work of the next process. Since the transfer means is controlled so that the workpiece is carried into the warehouse and subsequently the jig pallet and parts are supplied to the first work station, the work delay at the second work station in the first work station, etc. It is possible to immediately start the next assembling work without being affected by the above, and the work efficiency is improved without waiting for the work.
[0039]
Further, if the work at the second work station is performed by an automatic device that automatically performs the next process work on the work, the work that is difficult for the operator to perform manually is performed by the automatic device. Work efficiency is improved and labor costs are reduced. In particular, if a sealing agent application device that automatically applies a sealing agent to a workpiece is used as an automatic device, the sealing agent application operation that is difficult for an operator to perform manually and is likely to cause quality variations is automatically performed. As a result, work efficiency is improved and stable quality is obtained.
[0040]
In addition, since the leak test is automatically performed on the workpiece with the parts assembled after applying the sealant, the leak test, which is likely to cause an inspection failure if performed manually by the operator, can be automated, improving the work efficiency and the inspection failure. It is possible to prevent the shipment of defective products.
[0041]
According to a fifth aspect of the invention, there is provided an assembly production method according to the fourth aspect , wherein the first work station includes a plurality of parts places, so that an operator can remove parts from one parts place. Even during the picking up operation, parts can be supplied to the other parts storage area by the transport means, so there is no waiting time and work efficiency is improved, and the operator collides with the transport means. Can be prevented and the safety of workers is ensured.
[Brief description of the drawings]
FIG. 1 is a schematic plan view of an assembly production system according to an embodiment.
FIG. 2 is a perspective view showing an assembly operation of a jig pallet and parts according to the present embodiment.
FIG. 3 is a perspective view showing an intermediate product according to the present embodiment.
FIG. 4 is a perspective view showing a second intermediate product according to the present embodiment.
FIG. 5 is a perspective view showing a third intermediate product according to the present embodiment.
FIG. 6 is a perspective view showing a fourth intermediate product according to the present embodiment.
FIG. 7 is a perspective view showing a finished product according to the present embodiment.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 1st work station 2 2nd work station 3 Warehouse 4 Transfer means 5 Control means 6 2nd transfer means 7 Worker 10 Assembly production system 11 Jig pallet 12 Parts 13 Intermediate product 13a Second intermediate product 13b Third intermediate product 13c Fourth intermediate product 14 Finished product 15 Sealant application device 16 Leak test device

Claims

A first work station for assembling parts on a jig pallet;
A second work station provided with a sealant application device for performing a sealant application work that is a work of the next process on a work assembled with parts in the first work station;
A warehouse for storing the jig pallet and parts;
Conveying means for carrying in and out the jig pallet and parts between the warehouse and the first work station, and carrying in and out the jig pallet between the warehouse and the second work station;
When the work at the first work station is completed, the jig pallet carrying the work is carried into the warehouse, and then the jig pallet and the parts to be assembled are supplied to the first work station, When the next process work on the work at the second work station is completed, the jig pallet on which the work is placed is loaded into the warehouse, and then the work to be worked on the next process is loaded. Control means for controlling the operation of the conveying means so as to supply a jig pallet to the second work station ,
The first work station is a station that also performs assembly work of parts to the work after application of the sealant,
The second work station is a station that also performs a leak test on a workpiece in which parts are assembled after application of the sealant, and includes a leak test device,
The control means carries the jig pallet on which the workpiece after application of the sealant is placed and the parts to be assembled to the workpiece as a replacement of the workpiece on which the parts are assembled before application of the sealant to the first work station, The assembly is characterized in that the operation of the conveying means is controlled so that a jig pallet carrying a work to be subjected to a leak test is carried into the second work station as replacement of the work after application of the sealant. Production system.

In the assembly production system according to claim 1,
The assembly work system according to claim 1, wherein the first work station includes a plurality of parts storages for storing parts sequentially supplied by the transport means.

In the assembly production system according to claim 1,
An assembly production system comprising second conveying means for supplying the jig pallet and parts to the warehouse.

A warehouse for storing jig pallets and parts, a first work station for assembling the parts to the workpiece , a second work station for performing a sealant application operation , which is a work of the next process for the workpiece to which the parts are assembled, In the assembly production method performed using the transport means for transporting between the warehouse and each of the first and second work stations,
Step A for carrying out the jig pallet and parts from the warehouse to the first work station;
Step B for assembling parts on the jig pallet at the first work station;
A step C of carrying the work assembled with the parts from the first work station into the warehouse together with the jig pallet;
A process D for carrying out a jig pallet carrying a work to be performed in the next process from the warehouse to the second work station;
Step E for performing the next step work on the workpiece on the jig pallet at the second work station;
A process F for carrying the work, which has been completed in the next process from the second work station, into the warehouse ;
A process G for assembling parts to the workpiece after applying the sealant at the first work station;
Including a step H of performing a leak test on a workpiece in which parts are assembled after applying the sealant at the second work station ,
When the process B is completed, the conveying means is controlled to perform the process A following the process C,
When Step E above is finished, we have row the step D following the above step F by controlling the conveying means,
As the process B, the parts before applying the sealant are assembled on the jig pallet, and when the process B is completed, the process A following the process C is a process where the work after applying the sealant is placed. Carrying the tool pallet and the parts to be assembled to the workpiece into the first work station, assembling the parts,
As the process E, a sealant is applied on the jig pallet, and when the process E is completed, in the process D following the process F, a jig pallet on which a workpiece to be subjected to a leak test is placed is second. An assembly production method , wherein the leak test is carried into a work station .

In the assembly production method according to claim 4 ,
The assembly work method according to claim 1, wherein the first work station includes a plurality of parts storages for storing parts sequentially supplied by the conveying means.