JPH0236055A - Changeover method for production indication - Google Patents

Abstract

PURPOSE:To automatically perform the subtraction of a truncating residual number, the control of the truncation completion time and the starting time, the alarm output of a surplus part production time and the rise mark endowment for a new model by inputting the conditions on the product name relating to a model change, truncation start time, truncation residual number, etc., prior to truncation and rise processings. CONSTITUTION:After the production truncation starting time of an old model decrement is executed on the truncation residual number whenever the production indication of a product is performed, the time when the truncation residual number becomes zero is taken as a truncation completion time and the time adding the rise time to a new model to this truncation completion time as a starting time, and these truncation completion time and rise starting time are automatically stored by a memory device 22 on a truncation and rise list. In case of the production indication of a product being performed within this rise time, an alarm is sent by a warning signal device 25 and also a rise mark is given for the product to which the production indication is executed prior to the rise completion time and after the starting time.

Description

Detailed Description of the Invention (Field of Industrial Application) The present invention relates to a production instruction switching method, and more specifically, in a high-mix, low-volume production system, production of an old model is discontinued due to a change in product model, and production of a new model is started. The present invention relates to a production instruction switching method for automatically increasing production instructions.

(Prior Art) In a high-mix, low-volume production system, switching from an old model to a new model is relatively frequently performed due to model changes in similar products. In making this switch, after the model change has been decided, the remaining number of discontinued models (remaining production volume) is determined, and each time a product production instruction is issued, the remaining number of discontinued units is sequentially subtracted, until this number reaches zero. When this happens, instructions to produce the new model are given to the production line.

(Problem to be solved by the invention) However, in the past, production planners had to monitor the production line to prevent them from instructing the production line to produce the old model only after the remaining number of discontinued old models became relatively small. This is common, and production instructions given before this monitoring could result in excess production of older models. Further, even when subtracting the number remaining after discontinuation, there is a problem in that calculation errors are likely to occur because it is done manually.

Furthermore, when production of a new model is started immediately after the number remaining after discontinuation reaches zero, parts from the old model are often attached to the product of the new model due to errors in judgment by assembly workers. This has led to inconveniences such as the production of defective products and the need for a constant monitoring system. In particular, in the case of model changes, the new and old models are of the same type, and there is no effective means to distinguish between the old and new models on the production line, which is a major cause of defective products.

The present invention was proposed to solve the above problems, and its purpose is to subtract the remaining number of discontinuations, manage the discontinuation start time, and start up An object of the present invention is to provide a production instruction switching method that automates product model identification, etc., and prevents production of surplus quantities and generation of defective products.

(Means for Solving Problem A) In order to achieve the above object, the present invention provides a list of the product names to be replaced from the old model to the new model, the production discontinuation start time of the old model, the remaining number of discontinuations, and the old model. The start-up time from discontinuing the production of a model to starting the production of a new model, and the start-up end time of the new model are stored in advance as a discontinuation start-up table in the production planning instruction device, and after the discontinuation start time of Moeki. Then, each time a production instruction for a product is issued, the remaining number to be discontinued is decremented.

The time when the remaining number of censoring becomes zero is the censoring end time,
Moreover, the time obtained by adding the above-mentioned start-up time to this discontinuation end time is set as the start-up start time, and these discontinuation end time and start-up start time are automatically stored in the above-mentioned discontinuation start-up table, and the product is processed within the above-mentioned start-up time. The present invention is characterized in that an alarm is issued when a production instruction is given, and a start-up mark is given to a product for which a production instruction is given after the start-up time and before the start-up end time.

(Function) According to the present invention, after a decision is made to change the model for a certain product, a production planner can inform the product name, discontinuation start time, and remaining number of discontinuations for the model change.

By inputting the start-up time and start-up end time into the discontinuation start-up table of the production planning instruction device, the remaining number of discontinued old models is subtracted, and the discontinuation end time and start-up start time are automatically managed. , an alert will be automatically issued if surplus quantities of the old model are produced. Further, at the time of launch, a start-up mark is given to a new model product, and this mark is also notified to the production line, allowing line workers to clearly distinguish between the new and old models.

(Example) An embodiment of the present invention will be described below with reference to the drawings.

First, Fig. 2 shows the entire production system to which the present invention is applied, and this production system is for assembling, inspecting, etc., high-mix low-volume production products such as automobile engines. be.

In Fig. 2, 1 is a production management system consisting of a host computer, etc., 2 is a production planning instruction device consisting of a mini computer system installed in the factory, 3 is a data way such as a LAN using an optical cable, and 41 to 44 are production planning instructions. A data terminal for exchanging production instruction data, production performance data, etc. between the device 2 and the assembly line 51 and inspection line 52; 5 is a production line consisting of the assembly line 51 and inspection line 52; 6 is a product warehouse; are shown respectively.

Here, the production planning instruction device 2 includes a data processing device 21 such as a minicomputer connected online or offline to the production management system 1, and this data processing device 2I.
A storage device 22, a man-machine interface 23. It is composed of a printer 24 and an alarm device 25. Further, the data processing device 21 is equipped with a production instruction switching means 26 made of software for executing a series of switching processing consisting of processing for discontinuing production of the old model and processing for starting production of the new model, which will be described later.

Note that in this embodiment, the data processing device 21, the storage device i
'i 22, man-machine interface 23, printer 24, and alarm device 25 have been explained as components of the production plan instruction device 2, but these components not only provide instructions for production planning, but also provide equipment operation management and production results. It is also capable of performing various types of management, control, alarm output, etc. associated with product production, such as management and quality control.

Next, the discontinuation start-up process from the old model to the new model in this embodiment will be explained with reference to the flowchart of FIG. 1 and FIG. 2.

In Fig. 1, first, according to instructions from production line 5,
The data processing device 21 searches for the name of the product to be produced next (in-process instruction) from the production sequence table created in advance (step S
L). Note that this production order table is stored in the storage device 22 or the like. Next, it is determined whether the product name is registered in the discontinuation/launch list (S2).

This discontinuation/launch table can be created at any time after the decision to change the model for a certain product, including the product name, the production discontinuation start time of the old model, the remaining number of discontinuations, the production launch time and launch date of the new model. It is created by the production planner inputting the end time via the man-machine interface 23, and when input, it is displayed on the display for each product whose model is changed, and after input, it is stored in the storage device 22, etc. It is something that

The discontinuation start-up table is configured, for example, as shown in the following Table 1 before the discontinuation start-up process is started. (Hereinafter, blank space) Table 1 In this Table 1, the discontinuation start time is the start time of discontinuation processing for the old model of product A, and
The remaining number of products to be discontinued is automatically decremented each time a production instruction for an old model is issued.

Further, the cutoff end time is initially blank, and the time when the cutoff remaining number becomes zero is automatically input. In addition, the startup time is preset as the margin time from the end time of discontinuation until the production of the next new model is instructed, and workers on the assembly line 5I and inspection line 52 can change Prepare the parts, tools, inspection instruments, etc. required for changing to a new model, and the start-up start time is initially blank, and the time to start production of the new model and the start-up end time are set. It means the end time of the new model startup process, that is, the time when a series of model switching processes end.

In the previous step S2, if the product to be discontinued and launched is A, this is because this product A is registered in the discontinuation and launch table.

In the next step, it is determined whether the current time has passed the abort start time (step S3). In addition,
If product A is unregistered, it is assumed that the model will not be changed, and the assembly line 51 is instructed to proceed with product A (S9).

In step S3, if the current time has passed the abort start time, the next step is to determine whether the abort end time is stored in the abort start table (
Same S4). Furthermore, if the current time is before the abort start time, the process advances to step S9.

In step S4, if the discontinuation end time has not been stored yet, the discontinuation process is currently in progress, so the remaining discontinuation number in the discontinuation start-up table is decremented each time a production instruction for product A is issued (step S5). and 1
Next, it is determined whether the remaining number of censoring is zero or not in S6.
), if it is not zero, sends an in-process instruction for the product A to the assembly line 51 (S9). On the other hand, if the remaining number of aborts is zero, the current time is automatically stored in the abort start table as the abort end time (S7).

Next, the start-up start time, which is the time when the start-up time (3 hours) is added to this abort end time, is automatically stored in the abort-start table (S8), and the process proceeds to step S9.

In addition, if the abort end time has already been stored in the previous step S4, that is, if the abort process has ended, it is then determined whether the current time is before the start-up start time (same as 510). Here, if it is before the start-up start time, the remaining number to be discontinued will be decremented every time a production instruction for product A is issued, but at this point,
Since the remaining number of aborts has already become zero due to the end of the abort process, the remaining number of aborts becomes negative by the above decrement (S11).

This state is an abnormal situation in which production instructions for the old model are being continued during the start-up time until the discontinuation process for the old model is completed and the start-up of the new model is started. The number of units produced can be ascertained, and in the first step, an alarm is issued by the alarm device 25 shown in FIG. 2 (512), and the process then proceeds to step S9.

Furthermore, if the current time is after the startup start time in the previous step SIO, it is determined in the first step whether the current time is before the startup end time (513
). If it is not before the start-up end time, that is, after the start-up end time, the start-up process has been completed and the process proceeds to step S9, and if it is before the start-up end time, the start-up process is currently in progress. Therefore, in order to make workers on production line 5 aware that product A currently being produced is a new model, an appropriate rising mark is added to a part of the product model identification label. 5 will also be notified (514). This allows line workers to clearly recognize that the product A being produced is a new model, thereby preventing mistakes from occurring when assembling one part.

If the start-up end time has already passed in step S13, the aborted start-up process due to the model change of product A ends at the start-up end time without adding a new start-up mark.

In addition, although the above embodiment describes the case where there is a single production line, the present invention can also be applied to a case where various product types are changed on multiple production lines using a single production planning instruction device. Furthermore, the type of product is not particularly limited to automobile parts or the like.

(Effects of the Invention) As described above, according to the present invention, prior to the discontinuation start-up process, the name of the product to be changed, the discontinuation start time,
By simply inputting the conditions such as the remaining quantity to be discontinued, production planners etc. can subtract the remaining quantity to be discontinued, manage the discontinuation end time and start-up start time, output alarms when surplus quantities are produced, and add start-up marks to new models. Processing can be done automatically. This has the effect of preventing errors in calculating the remaining number of products to be discontinued, and preventing excess production of old models and generation of defective products of new models without the need to constantly monitor the production line.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention, in which Fig. 1 is a flowchart showing a termination/startup process, and Fig. 2 is a configuration diagram of a production system. 1... Production management system 2... Production planning instruction device 5... Production line 21... Data processing device 22... Storage device 23゛... Man-machine interface 24... Printer 25... Alarm device 26... Production instruction switching means 51... Assembly line 52... Inspection line

Claims (1)

[Claims] In a production instruction switching method for switching production instructions for a production line from an old model to a new model in a production system for high-mix, low-volume production products using a production planning instruction device, the name of the product to be switched; The discontinuation start time and the remaining number of discontinuations of the old model, the start-up time from discontinuing the production of the old model until starting the production of the new model, and the end time of start-up of the new model are sent to the production plan instruction device. It is stored in advance as a production table, and after the discontinuation start time, the discontinuation remaining quantity is decremented every time a product production instruction is given, and the time when the discontinuation remaining quantity becomes zero is the discontinuation end time, and this discontinuation is The time when the start-up time is added to the end time is set as the start-up start time, and these discontinuation end time and start-up start time are automatically stored in the above-mentioned discontinuation start-up table, and product production instructions are issued within the start-up time. A production instruction switching method characterized in that a warning is issued when the start-up is performed, and a start-up mark is given to a product for which a production instruction was given after the start-up time and before the start-up end time.