JPH03142666A - Parts delivery instructing device - Google Patents

Abstract

PURPOSE:To evade such a case where the delivered parts are kept in custody for a long period at the assembly line side by changing automatically the ordering instruction from to a fixing instruction when the number of parts desired is decreased owing to the fluctuation of demand. CONSTITUTION:A sheet number calculation means 81 calculates the number of ordering instruction cards based on the number of parts required given from a production planning means 51. A 1st comparison means 82 compares the calculated number of ordering instruction cards with the number of ordering instruction cards set previously. At the same time, a 2nd comparison means 83 compares the parts delivery read time with the parts use read time. Then the ordering instruction form of parts is switched to a fixing instruction which designates the delivery time when the calculated number of cards is smaller than the set number of cards and the delivery read time is shorter than the use read time. Thus the delivery of parts is possible in accordance with the fluctuation of demand and to evade such an inconvenient case where the delivered parts are not used for a long period.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a parts delivery instructing device that instructs the delivery of parts to be delivered to an assembly factory for, for example, vehicles, and in particular, the present invention relates to a parts delivery instructing device that instructs the delivery of parts to be delivered to an assembly factory for, for example, a vehicle. The present invention relates to a parts delivery instruction device that automatically switches.

[Prior Art] As a technical document related to the present invention, for example, "New Development of the Toyota Production System" published by the Japan Management Association is known. This document describes a computer information system that supports the so-called "Kanban" method. Further, as a prior art related to ordering articles, an order management device disclosed in, for example, Japanese Utility Model Application Publication No. 62-95852 is known.

By the way, in just-in-time production, in which necessary items are produced and transported in the necessary quantity at the necessary time, an ordering instruction card called a "kanban" is used. This order instruction card is moved along with the parts and is used as production and transportation instruction information or as a visual management tool.

This ordering instruction card is employed, for example, as one means for instructing the delivery of parts from an assembly factory that assembles vehicles to a parts factory that manufactures parts. FIG. 4 shows an example of a parts delivery instruction using an ordering instruction card.

FIG. 4 shows the flow of information from parts ordering to delivery using the conventional kanban system. As shown in the figure, in step 1, a part 11 manufactured at a parts factory 18 as a parts manufacturer is transported by truck along with an order instruction card 12 to an assembly factory 19 as a parts user. In the assembly factory 19, the parts 11 are unloaded from the truck 14 at a place called a receiving area 13, and are transferred to a transport trolley. Then, as shown in step 2, the parts are transported to the vehicle assembly line 15 and assembled into the vehicle body.

When the parts are consumed on the assembly line 15, the ordering instruction card 12 is removed from the pallet containing the parts and placed in a collection post located near the assembly line 15. The order instruction card 12 placed in the collection post is
It is collected periodically and transported to the receiving area as shown in step 3. A delivery instruction device 16 is placed in the reception area 13, and the information on the order instruction card 12 is read by the reader 17 of the delivery instruction device 16, as shown in step 4. The delivery instruction device 16 grasps the type and quantity of parts to be instructed for delivery from the read information, and also issues a delivery note,
Create accounting documents such as receipts. The ordering instruction cards 12 read by the delivery instruction device 16 are sorted by parts factory as shown in step 5.

The pallet emptied by the consumption of parts on the assembly line 15 is transported by truck 13 to the parts factory 18 along with the created accounting form and ordering instruction card 12, as shown in step 6. At the parts factory 18, as shown in step 7, the received order instruction cards 12 and accounting forms are conveniently sorted and stored by assembly factory and truck.

When the specified time specified in advance arrives, the corresponding parts are collected in step 8 according to the number of order instruction cards 12. The order instruction card 12 and the accounting form are then shipped to the assembly factory 19 together with the parts, as shown in step 9. In this way, the ordering system shown in FIG. 4 is a post-replenishment system in which parts consumed in the assembly factory are ordered for the parts consumed on the premise that they will definitely be consumed next time. This method is effective in an environment where the same type of parts can be used continuously and in a uniform manner. Also, since it is based on actual usage, it is also a method that easily reflects the progress of work on the assembly line. be. Furthermore, even if a large quantity is consumed due to defective parts, etc., it has the advantage that it is possible to autonomously order more quantity.

[Problems to be Solved by the Invention] However, the above-mentioned kanban ordering system has the following drawbacks due to fluctuations in demand for products. In other words, in recent years, fluctuations in demand for products have tended to increase due to the diversification of products, but if parts ordering relies only on order instruction cards, there is a risk that the parts will actually be used after they are delivered. This can sometimes take a long time, and in just-in-time production without a warehouse, a situation has arisen in which storage space must be secured beside the assembly line to store the parts.

This goes against inventory reduction efforts, leads to a decrease in work space, and is a contributing factor to deterioration of production efficiency.

The present invention has focused on the above-mentioned problem, and an object of the present invention is to provide a parts delivery instruction device that can eliminate the situation where delivered parts are not used for a long period of time due to fluctuations in product demand.

[Means for Solving the Problems] A parts delivery instruction device according to the present invention that meets this objective includes: a production planning means for outputting a production plan for parts within a predetermined period; a number calculating means for calculating the number of ordering instruction cards to be distributed from the required number; a first comparing means for comparing the calculated number of ordering instruction cards with a preset value of the number of ordering instruction cards; and parts. a second comparing means for comparing the delivery lead time of the part and the usage lead time; and if the calculated number of parts from the number calculation means is less than the set value and the delivery lead time is less than the usage lead time, An ordering instruction form switching means for switching the ordering instruction form to a confirmed instruction from the production planning means specifying a delivery time, and otherwise switching the optical instruction form to a kanban instruction using the ordering instruction card. Consists of.

[Operation] In the parts delivery instructing device configured as described above, first, the production planning means outputs a production plan for parts within a predetermined period. When the production plan is output, the number of order instruction cards to be distributed is calculated by the number calculation means from the required number of parts. The first comparing means compares the calculated number of ordering instruction cards with a preset value of the number of ordering instruction cards, and the second comparing means compares the delivery lead time and usage lead time of the parts. be compared.

In this case, if the number of parts calculated by the number calculation means is less than the set value and the delivery lead time is less than the lead time used, the production planning means changes the part ordering instruction form to specify the delivery time by the ordering instruction form switching means. It is switched to the confirmation instruction from . In other words, when the required number of parts decreases due to demand fluctuations, the ordering instruction form is automatically changed to a confirmed instruction. Therefore, it is possible to avoid a situation in which delivered parts are stored beside the assembly line for a long period of time.

In cases other than the above, the ordering instruction format is switched to a kanban instruction using an ordering instruction card by the ordering instruction format switching means, and orders are placed based on the conventional ordering instruction card.

[Embodiments] Below, preferred embodiments of the parts delivery instruction device according to the present invention will be described with reference to the drawings.

1 to 3 show an embodiment of the present invention, and particularly show a case where the present invention is applied to a production factory that produces vehicles. In the figure, 21 indicates a parts delivery instruction device. The parts delivery instruction device 21 includes a barcode reader 31, a printer 32, a CRT (cathode ray tube) 33, a keyboard 34, and a printer 32 disposed in an assembly factory 30 where vehicles are assembled.
Control means 35, storage means 36, interface (I/F
) 37, and a control means 41 disposed in a parts factory 40 that manufactures parts. It is composed of an ordering instruction card creation means 42, a form creation means 43, and an interface 44. In addition, interfaces 37 and 44 at both factories are communication circuits I! It has a function of exchanging information via 54.

A production planning means 51 consisting of a host computer is connected to the control means 35 of the assembly factory 30 via a communication line IjI55. The production planning means 51 has a function of formulating, for example, monthly and daily production plans. The monthly production plan is called unofficial information, and this unofficial information is predictive information of the required amount of each part for the month, and at the end of the month, unofficial information for the next station is sent to the control means 35. On the other hand, the daily production plan is called confirmed information, and vehicles are actually produced based on this confirmed information. The confirmed information is sent to the control means 35 about three days before the completion of the vehicle.

The control means 35 of the assembly factory 30 includes a barcode reader 3.
1. printer 32, cathode ray tube 33, keyboard 34,
A storage means 36 and an interface 37 are connected.

Connected to the control means 41 of the parts factory 40 are an ordering instruction card creation means 42, a form creation means 43, and an interface 44.

The barcode reader 31 in the assembly factory 30 has a function of reading information on an order instruction card 61 created at a parts factory.

FIG. 3 shows an example of the ordering instruction card 61. In the figure, 62 is the part code, 63 is the delivery location, code 64 is the delivery location (converted from the delivery location code), 65 is the delivery date and time, 66 is the number of units accommodated, 67 is the part abbreviation number (converted from the part code), and 68 is Parts factory code, 69 is parts factory name (converted from parts factory code), 70 is serial number, 71 is delivery order, 7
2 each indicate a barcode. barcode 72
is a signal of these ordering information, and this barcode 72 is read by the barcode reader 31.

The control means 35 of the assembly factory 30 is composed of, for example, a microcomputer, and includes a number calculation means 81, a first
, a second comparing means 83 , and an ordering instruction type switching means 84 . The number calculating means 81 has a function of calculating the number of order instruction cards to be distributed from the required number of parts inputted from the production planning means 51.

The first comparing means 82 has a function of comparing the calculated number of ordering instruction cards 61 with a preset value of the number of ordering instruction cards 61. The second comparison means 83 is
It has a function to compare parts delivery lead time and usage lead time. The ordering instruction format switching means 84 is
If the calculated number of parts from the number calculation means 81 is less than the set value and the delivery lead time is less than the used lead time, the function switches the part ordering instruction form to a confirmation instruction from the production planning means 51 that specifies the delivery time. have Also,
In cases other than the above, the ordering instruction format switching means 84
It has a function of switching the ordering instruction format to a kanban instruction using an ordering instruction card 61.

The storage means 36 has a function of storing information from the production planning means 51 and information from the barcode reader 72. The printer 32 and the cathode ray tube 33 similarly have the function of displaying information from the production planning means 51 and the barcode reader 72. The keyboard 34 is used, for example, when transmitting information from the assembly factory 30 to the parts factory 40.

The control means 41 of the parts factory 40 issues an order instruction card 61 and a form (
Order instruction card means 42
and a function of outputting to the form creation means 43, respectively. The ordering instruction card creation means 42 generates the ordering instruction card 6 shown in FIG. 3 based on the information output from the control means 41.
Similarly, the form creating means 43 has a function of creating a form based on the information output from the control means 41.

The ordering instruction card 61 and documents such as delivery notes created at the parts factory 40 are delivered to the assembly factory 30 by the truck 71 along with the parts (as shown) by a predetermined date.

Next, the operation of the above-mentioned parts delivery instruction device will be explained.

First, before explaining the information processing procedure of this device, the contents of the information stored in the storage means 36 will be explained. As shown in Table 1, the storage means 35 of this device has pre-registered the instruction format, number of units accommodated, delivery lead time, use lead time, and minimum number of kanban sheets for each part.

The meaning of each information in Table 1 is as follows.

Capacity: Number of parts stored on one pallet Delivery lead time: Time required from issuing delivery instructions to the parts factory until parts are delivered to the assembly factory Usage lead time: Confirmed information Minimum number of kanban sheets required for the time required from receiving the item to using the part...This is a preset value,
If the average number of kanbans issued per day falls below this value, a final instruction will be issued.

Instruction format...Pa 1'': Kanban instructions (as before, when the kanban is read, give instructions for the amount read)> “2”: Confirmed instructions (when it is known that it will be used at the time of receiving the confirmed information Delivery lead time Next, a series of processes in this device will be explained based on the flowchart in Fig. 2. In step 101 in the figure,
At the end of the month, unofficial information about the next station is input from the production planning means 51 to the control means 35. Upon receiving the unofficial information, step 10
2, the number calculation means 81 calculates the number of daily order instruction cards 61 for each component (kanban number) as shown below (1
) is calculated based on the formula.

Number of kanbans (sheets/day = required number (fIi!)/day) Number of kanbans accommodated (1) When the calculation of the number of kanbans is completed, the process proceeds to step 103, and the second comparing means 83 compares each part. The delivery lead time and usage lead time are compared for:
If the delivery lead time is larger than the usage lead time, the final instructions will not be enough to complete the delivery, so step 10
The process proceeds to step 5, where the instruction form is set to "kanban instruction" by the ordering instruction form switching means 84, and the process proceeds to step 108. Conversely, if the use lead time is larger than the delivery lead time in step 103, the process proceeds to step 104, where the first comparison means 82 compares the number of kanbans with the lower limit number of kanbans. Here, if the number of kanbans is greater than or equal to the lower limit number of kanbans, step 105
, the instruction form is set to "Kanban instruction j," and the process goes to step 108.In step 104, if the number of kanbans falls below the lower limit number of kanbans, step 1
06, the instruction form is set to "confirmation instruction" by the order placement instruction form switching means 84. When the instruction form is switched to a confirmed instruction, the process proceeds to step 107, where the number of improved accommodations is calculated using the following equation (2).

Minimum number of kanbans (sheets/day) ・・・・・・(2) In this way, the minimum number of kanbans is secured by reducing the number of parts stored on a pallet with at least one required number of parts to the set number or less. This is to realize "Kanban instructions".

The improved accommodation number determined by the calculation is the printer 32,
A list of confirmed parts is displayed through the cathode ray tube 33 as shown in Table 2.

Next, at the assembly factory, when the kanban information is read from the ordering instruction card 61, the instruction form is searched, and if it is a "kanban instruction", parts are ordered based on the kanban instruction as before. On the other hand, if it is a "confirmed instruction", no parts will be ordered. On the other hand, when the confirmation information is received, the instruction form is searched for each part, and the "confirmation instruction" is
If so, the delivery instruction will be issued at a point in time that is ahead of the date of use by the delivery lead time.

Note that although it is not necessary for the ordering instruction card 61 for the finalized parts to be read at the assembly factory, in terms of standardization of work procedures, it is preferable that all ordering instruction cards 61 be read at the assembly factory. In addition, for confirmed instruction parts,
If the number of accommodations is improved to be less than or equal to the improved number of accommodations and set to a new number of accommodations, the process from step 104 in FIG. 2 is performed, and the instruction form is set to "kanban instruction".

Additional instructions due to component defects are given via the keyboard 34.

Note that if unofficial information is not available for some reason, or if the accuracy is very poor even if it is available, processing is performed using past results (for example, last month's results) as a substitute for unofficial information.

[Effects of the Invention] As explained above, when using the parts delivery instruction device according to the present invention, the number of order instruction cards is calculated by the number calculation means based on the required number of parts from the production planning means,
A first comparing means compares the calculated number of ordering instruction cards and a preset value of the number of ordering instruction cards, and a second comparing means compares the delivery lead time and usage lead time of the parts. If the calculated number of parts from the number calculation means is less than the set value and the delivery lead time is less than the used lead time, the parts ordering instruction format is switched to a confirmation instruction that specifies the delivery time; otherwise, the ordering format is changed to "Order". By switching to kanban instructions using instruction cards, it is possible to deliver parts in accordance with demand fluctuations, and it is possible to eliminate the situation where delivered parts are not used for a long period of time.

Therefore, in just-in-time production without a warehouse, there is no need to secure a storage space beside the assembly line to store the parts, and the inventory of parts can be reduced.

In addition, when changing the ordering instruction form from a fixed instruction to a kanban instruction, the improved capacity can be indicated by the ordering instruction mode switching means, so it is possible to reduce the number of orders to a smaller lot according to the capacity.
can be promoted.

[Brief explanation of the drawing]

Fig. 1 is a schematic configuration diagram of a parts delivery instruction device according to the present invention, Fig. 2 is a flowchart showing an information processing procedure in the device of Fig. 1, and Fig. 3 is an ordering process used for information transmission in the device of Fig. 1. FIG. 4 is a plan view of the instruction card. FIG. 4 is a delivery information summary diagram showing the flow of delivery information in the conventional parts delivery method. 21...Parts delivery instruction device 30...Assembly factory 35...Control means 36...Storage means 40...Parts factory 51... ... Production planning means 81 ... Number calculation means 82 ... First comparison means 83 ... Second comparison means

Claims (1)

[Scope of Claims] 1. Production planning means for outputting a production plan for parts within a predetermined period; and a number calculation for calculating the number of order instruction cards to be distributed from the required number of said parts inputted from said production planning means. means, a first comparing means for comparing the calculated number of ordering instruction cards and a preset value of the number of ordering instruction cards, and a second comparing means for comparing the delivery lead time and usage lead time of parts. means, and when the number calculated by the number calculation means is less than the set value and the delivery lead time is less than the usage lead time, the part ordering instruction form is changed from the production planning means specifying the delivery time. A parts delivery instruction device comprising: an order instruction format switching means for switching to a confirmed instruction, and otherwise switching the order instruction format to a kanban instruction using the order instruction card.