JPH03228532A - Sequence line order control of mixed production line - Google Patents

Abstract

PURPOSE:To correct the order of delivary, and improve the straightening action by forming a storage with multiple storage lanes, and straighening a turbulence of the production sequence, and furthermore, adding an express lane and an out-of-service lane in parallel with the storage lanes. CONSTITUTION:A storage 3 is provided between an upstream production process 1 and a downstream production process 2, and multiple storage lanes 4a-4e are comprised therein. Firstly, a material is stored in order from the storage lane 4a on the basis of a priciple of first-in, first-out, and next, a material follows to a material A of the production sequence line near to oneself among the low numbers for storage. Furthermore, a principle is that when a lower number does not exist, a material is stored in a storage lane having the production sequence line most nearly to ownself in the last thereof. An express lane 9 and an out-of-service lane 10 are provided for addition to the described, and the express rane 9 carries a material to the downstream production process with the priority. In the out-of-service lane 10, in the case that a material of which production sequence is minimum exists later than the front, a material before oneself is sent to the storage side, and a material of which production sequence is minimum is carried with priority.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a ranking control method in a mixed production line, such as an automobile assembly line, in which a plurality of types of products of different vehicle types are mixed and sent through the production line.

An automobile production line usually consists of a wear-and-tear process, a painting process, a decoration process, etc., but due to sales policies and market demands, there are so-called production lines where multiple types of cars with different specifications are produced on the same production line. A mixed production line system is adopted.

As a result, there is a problem in that the number of man-hours in each process differs depending on the vehicle model. Therefore, it is possible to balance the man-hours by leveling the production order, but the demands for leveling each process such as melting, painting, and annotation do not necessarily match, and each process - leveling order is considered. is difficult to create. Further, even if a leveling order that extends through each process could be created, rework is unavoidable in the erosion process and painting process. When making such modifications, the production car body is first removed from the production line and then rejoined the production line after the modification, which causes the predetermined production order to fluctuate, making it impossible to maintain the leveled order. There is a problem.

Therefore, in the past, a method has been adopted in which storage is provided between each process, the produced car bodies are stored by type, and then reassembled to meet the requirements of the next process. but,
It is very difficult to rearrange products in storage between each process, and storing them by type breaks the entire predetermined production order, which tends to amplify the disorder in the order. Furthermore, storing produced vehicle bodies by type requires a large storage space, making it difficult to manage the produced vehicle bodies.

This invention was made in view of the above circumstances, and its purpose is to allow production to proceed according to a predetermined production order, even if the production order is disrupted due to branching, merging, etc. in the upstream production process. It is an object of the present invention to provide a method for controlling a sequence in a mixed production line, which allows the process to be rectified into a production sequence or a similar sequence in storage, and to be sent to a downstream production process.

That is, the first invention provides a storage at a relay point between an upstream production process and a downstream production process that flow multiple types of products with different production conditions in the order of their production order, and stores the products carried out from the upstream production process. After being temporarily stored in storage, in a mixed production line where it is delivered to the downstream production process, the above storage is placed in multiple rows of first-in, first-out storage lanes with designated priorities, and in parallel to the same storage lane and stored in the same storage lane. It consists of an express lane that transports manufactured goods from the upstream production process to the downstream production process with priority over the manufactured goods that are in the warehouse, and a forwarding lane that transports the manufactured goods discharged from the storage lane to the receiving side again. The first basic principle is to assign serial numbers to production parts in the order of their production order, and to store the produced goods carried out from the upstream production process into the storage lane in order of priority, in descending order of number. When the production order is disrupted due to merging, etc., if there is a production product with a younger number than you at the end of the production products already stored in the storage lane, the production order closest to you among them The second principle is that if there is no produced product with a lower number than the produced product that is placed in stock after a produced product, the product is stored in an empty storage lane where no produced product is stocked, and if there is no empty storage lane and the The fourth principle is that when a product with a lower number than all the products already in the storage lane is stored in the storage, it is introduced into the above-mentioned express lane and taken out first. If there is no empty storage lane at the end of the product that has been stocked because it is a product with a lower number than the product that is being stocked from the above-mentioned upstream production process, the storage lane will be filled with all the products that have already been stocked. The fifth principle is to store the product that is received from the above-mentioned upstream production process in the storage lane where the product with the highest production sequence number is stored, and to store the product that has already been stocked in the storage lane. When the smallest product in the middle production order is the second or later from the front row of the same storage lane, the product in front of the smallest product is taken out from the same storage lane and forwarded to the receiving side again by the forwarding lane. The sixth principle is to give priority to the smallest produced goods above,
This first. Second. 4th. Fifth. The gist of this invention is a method for controlling the order in a mixed production line, which is characterized by ordering the products in accordance with the sixth principle and transporting them to the downstream production process.

In addition, the second invention is based on the fifth principle that there is no product with a lower number than the product that has been stocked from the upstream production process at the end of the product that has already been stocked in the storage lane, and there is no empty product. If there is no storage lane, search for a product in each storage lane that has a production order number higher than the product that is to be stored above among the products that have already been stored, and that has a production order that is closest to the product that is to be stored above. , is characterized in that the product with the highest production order number among them is stocked.

Embodiments of the present invention will be described below with reference to FIGS. 1 to 3.

1 is an upstream production process such as a painting process, and 2 is a downstream production process such as a greening process.

Then, the unloading section 1a of the upstream process 1 and the downstream production process 2
A storage 3 is provided between the loading section 2a and the loading section 2a. Upstream production process 1 and downstream production process 2 are performed at low speed (2 to 3
It consists of a belt conveyor that runs (m/min), and is used to produce multiple types of products such as automobiles with different types, colors, etc.A.
..., and in the upstream production process 1, specified painting work is performed on the product A, and in the downstream production process 2, parts attachment work is performed on the finished product A. It has become. Furthermore, the above-mentioned product A... is manufactured according to the production order determined from the viewpoint of sales policy, market demands, etc.
. . . are given serial numbers of ○, and the products A . Further, the storage 3 has multiple rows, for example, first to fifth storage lanes 48 to 4.
Conveyors 7, which run only in six directions from the input side to the output side, are arranged in parallel. These conveyors 7 are divided into first to fifth stages 8a to 8e from the delivery side 6 to the receiving side, and one unit is provided for each of the first to fifth stages 8a to 8e. Product A... can be temporarily stored on a first-in, first-out basis. Further, the first to fifth storage lanes 4a to 4e are prioritized in their order, and the product A carried out from the upstream production process 1 is sequentially received from the first storage lane 4a according to the production order. The first basic principle is that If there is a product already stored in the first to fifth storage lanes 4a to 4e, and there is a product A with a smaller number than the product at the end of the product that has been stored, Among them, the product is placed in stock after the product A whose production order is closest to you,
When there is no produced article A with a lower number than one's own, the first to fifth storage lanes 4a to 4 where the produced article A is not stocked.
The second principle is to store vehicles in empty storage lanes.

Furthermore, if there is no production product with a smaller number than the production product A at the end of the production product A that has already been stored, and there is no empty storage lane among the first to fifth storage lanes 4a to 4e, The third principle is to store the product A in the production order closest to the storage lane 4a to 4e in which the product A is stored.

Therefore, the products A in the upstream production process 1 flow in descending numerical order according to a predetermined production order, but
If a coating defect occurs, it will be necessary to remove it from that line and rework it. Therefore, although a disturbance occurs in the production order, the disturbance can be corrected in the storage 3 and the product can be transported to the downstream production process 2. That is, the second
As shown in Figure (a), when the order of the products A carried out from the upstream production process 1 is ■■■■■■■@■◎ [phase], the first. Based on the second principle, up to 4b first stage 8a
In stock. Next, when [Stock] arrives, the last one stocked in the first storage lane 4a is the one with a lower number than itself and is the closest, so [Phase] is stored in the fifth stage 8e of the first storage lane 4a. In stock. Furthermore, when ■@ comes, these are sequentially stored after ■ in the second storage lane 4b, but when ■ follows [phase], the numbers younger than themselves are stored in the second storage lane 4b. 00 is stored in the first stage 8a of the third storage lane 4C, and 00 is stored in the fourth stage of the second storage lane 4b. Fifth
The products are sequentially stored in stages 8d and 8e.

Also, as shown in FIG. 2(b), if the above 0 is followed by ■ When carried out from upstream production process 1 in the order of 0, ■
to the third storage lane, [phase] to the fourth storage lane 4c, 4.
d respectively. Similarly to the above, since there is no number smaller than ■, the vehicle enters the fifth storage lane 4e. Furthermore, as shown in FIG. 2(C), the above
If ■ comes after , there is no number younger than you,
Moreover, since there is no empty space in each of the first stages 8a of the first to fifth storage lanes 4a to 4e, based on the third principle, the product A closest to oneself, that is, the product A in the fifth storage lane 4e, is Subsequently, it is stored in the second stage 8b.

Production goods A and 3 are stored in the storage 3 in this way.
. . . is the product A .
Among them, those with the lowest production rank are sequentially shipped from the warehouse and delivered to the downstream production process 3. Here, Fig. 2 (C)
The first to fifth storage lanes 4a to 4e as shown in
Describing the order of output of the stocked product A..., it is ■■■■■■■■[phase]■■o000, and Fig. 1 shows an example of the product A... The same technical parts are given the same reference numerals and their explanations will be omitted.

The storage 3 in this embodiment includes, in addition to the above embodiments,
An express lane 9 and a forwarding lane 10 are arranged side by side in the first to fifth storage lanes 4a to 4e. This express lane 9 is the first to fifth storage lanes 4a to 4e.
The product A is conveyed in the same direction as the storage lanes 4a to 4e, and the product A is transported from the upstream production process to the downstream production process, giving priority to the products stored in the first to fifth storage lanes 4a to 4e. Further, the forwarding lane 10 is connected to the produced goods A in the opposite direction to the first to fifth storage lanes 48 to 4e.
The first to fifth storage lanes 4a
The produced goods A that have been discharged from 4e to 4e are sent back to the warehousing side.

The first step in warehousing the produced goods according to this embodiment
The basics and the second basics are the same as those of the embodiment described above.

Next, in this embodiment, if there is a significant delay in unloading due to rework or the like in the upstream production process, in other words, there are no empty storage lanes and the first to fifth storage lanes 4a to 4e have already been stocked. In the case where the production order is lower than all the production items A, or it is received later than all the products A, to give a more specific example, as shown in Figure 3 (a), ■, which should be at the top, is extremely delayed. In such cases, the fourth principle is to introduce the vehicle into the express lane 9 and have it leave the garage first.

Next, as shown in FIG. 3(b), if ■ continues, the last @@◎ [phase] (main In the example, there is no product in the first storage lane 4a (excluding the first storage lane 4a because there is no storage space) that has a lower number than the product [phase] that is received from the above-mentioned upstream production process. When there are no empty storage lanes,
The third storage lane 4c is stocked with the product with the highest production order number among all the products already stored in the storage lane, that is, the product [F].
0 production items are stocked at . In addition, each storage lane 4
For each of a to 4e, among the already stocked products, the production order is thicker than the product [phase] to be stocked above (and the production order is closest to the production product [phase] to be stocked above) @■
Find 0■, and find the product with the highest production order■
The fifth principle is to store the produced goods (2) in the third storage lane 4C where the goods are stored.

The aim of the fifth basic principle is to:
Taking into consideration the time lag between forwarded production goods being re-stocked and ready for delivery to the downstream production process, maximize the time margin until the forwarded production goods are delivered to the downstream production process. It is to make it. In other words, in this embodiment, the product with the highest production order among the products already stored in the first to fifth storage lanes 4a to 4e is ■, and the product is delivered to the downstream production process in the order of the production order. In this case, it will be the final issue. Therefore, there is sufficient time to forward the produced goods @ to the warehousing side via the forwarding lane 10 and re-enter the warehouse, and the produced goods 0 to the third storage lane 4c where the produced goods By warehousing the production article 0, the production article 0 can be guided to the leading edge of the third storage lane 4c by forwarding the production article 2.

In this way, by providing the storage 3 controlled by the above storage method between the upstream production process and the downstream production process, as shown in FIG. (1) can be first taken out from the express lane 9, and subsequently from the first to fifth storage lanes 4a to 4e in ascending order of numbers.

Further, if the product A with the lowest production order among the products A already stored in the first to fifth storage lanes 48 to 4e is located in the second or later from the front row of each storage lane 4a to 4e, For example, as shown in Figure 3(C),
If there is a 0 in the first stage of the third storage lane 4c and there is a 0 to be delivered behind it, the [phase] is delivered and then forwarded to the receiving side by the forwarding lane 10,
The sixth principle is to give priority to the smallest ■ in the production order.

Here, the effects of the fifth basic and the sixth basic will be further explained based on FIG. 3(b) described above.

FIG. 3(b) shows that the product 0 is stored in the third storage lane 4c based on the fifth principle as described above, or if the product σφ is to be taken out, the product 0 is stored in the 6th storage lane 4c.
Based on this principle, the product [F] is forwarded through the forwarding lane 10 and then shipped out.

In this case, if we look at the time margin for the forwarded product @ to be re-stocked and ready for delivery to the downstream production process based on the difference in production order from product 0 currently being delivered to the downstream production process, 6(■-0). On the other hand, if the produced goods @ are stored in storage lanes 4b, 4d, and 4e other than the third storage lane 4C without following the fifth principle, the produced goods to be forwarded will be transferred to the second storage lane. When the product is stored in storage lane 4b, the product is @, and when it is stored in the fourth storage lane 4b, the product is [F],
When the product is stored in the fifth storage lane 4e, the product becomes 0. In other words, when the produced goods [phase] are stored in the storage lanes 4b4d and 4e other than the third storage lane 4c without being based on the fifth principle, the difference in the ranking with the forwarded produced goods @, ■, and ◎ is, respectively. 3 (
@−@)).

5 (O-■), 1 (■-[phase]), and the above-mentioned difference in rank is smaller than when warehousing is carried out based on the fifth basis. In other words, if you stock based on the fifth principle, the sixth
Based on this principle, it is possible to maximize the amount of time it takes for products to be sent to the warehouse to be re-stocked and ready for delivery to the downstream production process.

Here, in comparison with other conditions, in the case of condition 1, ``Among all the production goods that have already been stocked in the storage lane, the production sequence number is higher than that of the production goods to be stocked and the production of the production goods to be stocked is The production goods received from the upstream production process are stored in the storage lane where the production goods closest to the sequence number are stored.'' There is the following problem. In other words, the manufactured goods to be stocked are A,
If the product that meets the above conditions is B, then the product A
If the difference in the production order between the product B and the product B is small, the product A will be shipped out of the warehouse while the product B is being forwarded in the forwarding lane, and will take the order of product B. You will no longer be able to issue items in the correct order.

In the case of Condition 2, ``Products from the upstream production process are stored in the storage lane where the product with the highest production order number among all the products already stored in the storage lane is stored. ” When the storage lane for warehousing is determined under condition 2, there may be cases where product B, which is larger in production order and has a similar production order to product A that is received from the upstream production process, is stored in the selected storage lane. be. In this case, a problem similar to condition 1 occurs. That is, the sixth
According to the basic principle, it is necessary to take out product A before product B, so product B is forwarded to the receiving side using the forwarding lane. Unable to issue the item.

In the case of condition 3, "Among all the production goods that have already been stocked in the storage lane, the X (for example, 3rd) largest (smallest) production product in the production order is received from the upstream production process into the storage lane. There is a possibility that problems similar to conditions 1 and 2 will occur, and by determining the storage lane for warehousing based on the fifth principle above, it is possible to forward production goods that are already in stock. This makes it possible to select the optimal storage lane that allows sufficient forwarding time.

Furthermore, as shown in FIG. 3(d), the items sent by the forwarding tray 10 can be taken out again by being put into the fourth storage lane 4d in accordance with the second principle of the above-mentioned warehousing method. .

In the above embodiment, an express lane 9 and a forwarding lane 10 are provided for each lane, but the present invention is not limited to this, and multiple lanes may be provided, and the products to be produced are not limited to automobile bodies, but can vary by model. It can be applied to any production line as long as it mixes multiple types of products with different values and flows them through the production line.

As explained above, in the present invention, storage consisting of multiple rows of storage lanes is provided in the first . Based on the second and third basics, the products carried out from the upstream production process are arranged in order of production order or in a state close to it and then delivered to the downstream production process. This has the effect that even if there is a disturbance in the order, it can be rectified in the storage and sent to the downstream production process.

Furthermore, storage consisting of multiple rows of storage lanes plus express lanes and forwarding lanes is provided based on the above basics] and 2nd basics, and 4th. Based on the fifth and sixth basics, the products can be arranged in order of production order or in a state close to it. In other words, if the goods are received based on the fifth principle, and the produced goods to be forwarded according to the sixth principle are in storage,
A storage lane that can maximize the amount of time it takes for the forwarded product to be forwarded to the warehousing side by the forwarding lane, re-entered into storage, and ready for delivery to the downstream production process. It becomes possible to stock the produced goods, and it is possible to more effectively correct the disorder in the production order. In addition, when extremely delayed production occurs in the upstream production process, the express lane can be used to fully respond, and by using the forwarding lane, it is also possible to correct the shipping order within the same storage lane. This has the special effect of making it possible to improve the rectification effect.

[Brief explanation of drawings]

The drawings show an embodiment of the present invention; FIG. 1 is a schematic plan view of a production line, and FIG. 2(a) is a schematic plan view of a production line. (b) and (c) are also action explanatory diagrams, and Figures 3 (a) to (
d) is also an action explanatory diagram. 1...Upstream production process, 2...Downstream production process, 3...
・Storage, 4a to 4e...Storage lane, A
...Produced goods, 9...Express lane, 10...Forwarding lane.

Claims (2)

[Claims] (1) Storage was provided at the relay point between the upstream production process and the downstream production process, in which multiple types of products with different production conditions are passed in the order of their production order, and the products carried out from the above-mentioned upstream production process were temporarily stored in the storage. Later, in the mixed production line that transports to the downstream production process, the above storage is placed in multiple rows of first-in, first-out storage lanes with specified priorities, and is placed in parallel with the same storage lane and given priority over manufactured goods stored in the same storage lane. The system consists of an express lane for transporting manufactured goods from the upstream production process to the downstream production process, and a forwarding lane for transporting the manufactured goods discharged from the storage lane to the receiving side again. The first basic principle is to assign serial numbers in sequential order, and to store the products carried out from the upstream production process in the storage lane in descending order of priority. When a disturbance occurs, if there is a product with a lower number than you at the end of the products already stored in the storage lane, the product will be placed next to the product with the closest production order among them. The second principle is to store products in empty storage lanes where there are no produced products in stock when there are no produced products with a lower number than you. The fourth principle is that when products with a lower number than all the products in the storage are stored in the storage, they are introduced into the express lane and released first, and products that have already been stored in the storage lane are If there is no production product with a lower number than the production product received from the above-mentioned upstream production process at the end of the storage lane, and there is no empty storage lane, the production order number of all the production products already stored in the storage lane is The fifth principle is to store the production goods that are received from the above-mentioned upstream production process in the storage lane where the largest production goods are stored, and to store the production goods that are received from the above-mentioned upstream production process into the storage lane where the largest production goods are stored, and to store the production goods that are the smallest in the production order among the production goods that have already been stored in the storage lane. When an article is in the second or later row from the front row of the same storage lane, the article in front of the smallest produced article is taken out from the same storage lane and forwarded to the receiving side again by the forwarding lane, and the smallest produced article is given priority. The sixth principle is to leave the warehouse after the first, second, and fourth
A method for controlling the order in a mixed production line, characterized in that the products are arranged in order according to the fifth and sixth principles and then transported to the downstream production process. (2) Storage was provided at the relay point between the upstream production process and the downstream production process, in which multiple types of products with different production conditions are passed in the order of their production order, and the products carried out from the above-mentioned upstream production process were temporarily stored in the storage. Later, in the mixed production line that transports to the downstream production process, the above storage is placed in multiple rows of first-in, first-out storage lanes with specified priorities, and is placed in parallel with the same storage lane and given priority over manufactured goods stored in the same storage lane. The system consists of an express lane for transporting manufactured goods from the upstream production process to the downstream production process, and a forwarding lane for transporting the manufactured goods discharged from the storage lane to the receiving side again. The first basic principle is to assign serial numbers in sequential order, and to store the products carried out from the upstream production process in the storage lane in descending order of priority. When a disturbance occurs, if there is a product with a lower number than you at the end of the products already stored in the storage lane, the product will be placed next to the product with the closest production order among them. The second principle is to store products in empty storage lanes where there are no produced products in stock when there are no produced products with a lower number than you. The fourth principle is that when products with a lower number than all the products in the storage are stored in the storage, they are introduced into the express lane and released first, and products that have already been stored in the storage lane are If there is no production product with a lower number than the product stocked from the above-mentioned upstream production process at the end of the storage lane, and there is no empty storage lane, the top of the production products that have already been stocked will be stored for each storage lane. The production sequence number is higher than the produced goods,
In addition, the product with the production sequence number closest to the product to be stored is searched, and the product to be stored from the upstream production process is stored in the storage lane where the product with the highest production sequence number is stored. The fifth principle is to stock the storage lane, and if the smallest production product in the production order among the production products already stocked in the storage lane is in the second or later from the front row of the same storage lane, the smallest production product The sixth principle is to unload the forward produced goods from the same storage lane and forward them to the receiving side again by the forwarding lane, and to prioritize and unload the above-mentioned smallest manufactured goods, and the first, second, fourth, A method for controlling a sequence in a mixed production line, characterized by arranging products according to the fifth and sixth principles and transporting them to a downstream production process.