JPH04326468A - Classification control system of manufacturing line - Google Patents

Abstract

PURPOSE:To obtain a classification control system of the manufacturing line capable of outputting the classification instruction based on the actual packing result in the packing process. CONSTITUTION:The system is constituted of a factory host computer 10 preparing the classification/shipment plan based on the preliminarily drafted product process schedule data, a packing control part 6 outputting the actual packing result data in the packing process, a classification control part 15 inputting the actual packing result data outputted from this packing control part 6 and the classification/shipment schedule data outputted from the factory host computer 10, performing the classification processing of the packed products based on the actual packing result data in accordance with the preliminarily set classification pattern and outputting the classification instruction based on the classification processing, a classification device 17 classifying the packed products carried in accordance with the classification instruction outputted from this classification control part 15.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention is applicable to make-to-stock production.
The present invention relates to a sorting management system for a production line, which includes a packaging process for packaging products transported from a manufacturing process, and a sorting process for sorting each packaged product packed in a cardboard box in this packaging process.

0002

[Background Art] When scheduled production products are shipped to multiple delivery points in a planned manner, a shipping instruction sheet is traditionally created in advance based on a shipping plan drawn up in advance, and the items are sorted and shipped according to this shipping instruction sheet. A commonly used method is to give instructions.

That is, at the work site, shipping plan data in accordance with the work instructions is input into a computer at the site in accordance with the shipping instructions, and shipping instructions are issued in accordance with this input data.

[0004] Also, at this time, a bar code or magnetic strip is attached to the shipping instruction sheet, and a reader installed between the processes reads the results and automatically inputs them into the computer, thereby replacing the conventional manual work. Efforts have also been made to reduce the number of man-hours required for input processing.

[0005]

[Problems to be Solved by the Invention] The above-mentioned conventional method has the advantage of reducing the number of man-hours required to input shipping records and enabling real-time performance management by attaching barcodes or magnetic strips to shipping instructions. . however,
The shipping instructions are created in accordance with the shipping plan based on the production process plan, so if a product that differs from the production process plan is manufactured at the manufacturing stage due to a defective molding machine or an interruption in the rush item, etc. In this case, it is necessary to reissue the shipping instructions, which causes problems such as an increase in input man-hours.

[0006] Furthermore, if the actual manufacturing results are lower than the manufacturing plan, it is necessary to distribute shipments in a way that is as optimal as possible for each delivery point. Since doing so requires a great deal of work and labor, there was a problem in that in reality, distribution and shipment had to be carried out manually.

The present invention has been made in view of the above-mentioned circumstances, and its purpose is to enable the output of sorting instructions in accordance with the packaging results in the packaging process, so that the manufacturing process can be basically carried out in accordance with the production process plan. An object of the present invention is to provide a sorting management system for a production line that can issue work instructions for subsequent packing and sorting processes in accordance with the production results when the actual results deviate from the production process plan.

[0008]

[Means for Solving the Problems] In order to solve the above-mentioned problems, the sorting management system of the present invention includes a packaging process in which products transported from the manufacturing process are packed, and each product packed in a cardboard box in this packaging process. In a manufacturing line equipped with a sorting process for sorting packaged items, a factory host computer creates a sorting and shipping plan based on pre-planned production process plan data, and a factory host computer that creates a sorting and shipping plan based on the molding performance data sent from the manufacturing process. a packaging management department that issues packing instructions and outputs the packaging performance data; the packaging management department outputs the packaging performance data; and the sorting and shipping plan data output from the factory host computer are input; There is a sorting management section that sorts the packaged items based on packing performance data according to a preset sorting pattern, and outputs sorting instructions based on the sorting process, and the sorting instructions that are output from this sorting management section. The system is equipped with a sorting device for sorting packed items.

[0009]

[Operation] The factory host computer is provided with daily, weekly, or monthly production process planning data created by a molding process scheduling machine. The factory host computer creates a packaging plan and a sorting/shipping plan according to this production process planning data, and supplies the created packing plan data and sorting/shipping plan data to the packaging management department and the sorting management department, respectively.

The packaging management department issues post-processing instructions, packaging instructions, printing instructions, etc. based on molding performance data sent together with the molded product from the manufacturing process.

That is, if there is a molded product that requires post-processing such as screwing on a cap or attaching a seal, these instructions are given to the packaging process. In addition, instructions for carrying out the cardboard box for packaging, printing instructions on the cardboard box (printing a barcode, which is data such as product number information, etc.) are given to the packaging process.

[0012] Then, the packaging management section sends the packaging performance data of the actual packaging and transportation to the sorting process to the sorting management section.

[0013] The sorting management department performs packaging based on the packing performance data according to a preset sorting pattern based on the packaging performance data sent from the packaging management department and the sorting/shipping plan data output from the factory host computer. Performs sorting of products.

[0014] In other words, when the packing record data matches the sorting/shipping plan data, a sorting instruction according to the sorting/shipping plan data is output to the sorting device, and it is determined that the packing record data and the sorting/shipping plan data are different. in case of,
Based on the packing performance data, sorting instructions according to a preset sorting pattern are output to the sorting device.

Here, as an example of the sorting pattern, (
1) A pattern for sorting based on ratio distribution priority, (2) a pattern for sorting according to a preset shipping priority order, (3)
There are three composite patterns that are a combination of a proportional allocation priority pattern and a shipping priority pattern.

[0016] In addition, the sorting management department distributes the packing performance data according to each of the above-mentioned patterns, and then outputs the distribution results to the factory host computer, and the factory host computer performs subsequent sorting and shipping based on the distribution results. The plan data is re-created and processes such as supplying it to the sorting management department again are performed.

[0017] That is, when the packing performance data matches the sorting/shipping plan data, a sorting instruction according to the sorting/shipping plan data is output to the sorting device, and it is determined that the packing performance data and the sorting/shipping plan data are different. in case of,
Since the sorting instructions are given according to the sorting pattern, flexible sorting instructions that match the actual situation at the site and speedy and waste-free work are possible.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram showing the electrical configuration of a manufacturing line including a sorting management system according to the present invention.

[0020] In the production line of this embodiment, molding is carried out 24 hours a day using FMS equipment, while the packing process is carried out manually by workers only during the day shift, and the molded products are transported in units of a certain number (for example, units of 100 pieces). ) to be transported to the next process.

In the figure, a molding machine control unit 2 that sends molding instructions to a molding machine 1 is bidirectionally connected to a molding group management unit 3 that manages a plurality of molding machines 1 installed on a molding line. It becomes. Further, the output of the molding group management section 3 is connected to a data recording section 4 that records the molding results for each transport unit of molded products molded by each molding machine 1. In response to a writing instruction from the unit 3, the molding performance data is written by radio waves in the microwave band onto the recording medium 12 attached to the conveyance device 11 loaded with a predetermined number (for example, 100 molded products). There is.

[0022] Also, a packaging management section 6 manages the packaging process.
sends instructions for preparing auxiliary materials, post-processing and packaging instructions, etc. to the terminal machine 8 installed in the packaging process, and also sends instructions to the printing machine 9.
It sends printing instructions, etc. to the cardboard box. Also,
The packaging management section 6 is connected to the output of a data reading section 7 that reads molding performance data from a recording medium 12 attached to a transport device 11 loaded with a predetermined number of molded products and transported. Further, the packaging management section 6 is bidirectionally connected to a warehouse management section 13 that manages a storage process in which work-in-progress items are temporarily stored in a warehouse.

[0023] Furthermore, the sorting management unit 15, which manages the sorting of cardboard boxes to the delivery destination, sends sorting instructions to the sorting device 17 installed in the sorting process, and
The sorting management section 15 is led to the output of a barcode reading section 16 that reads a barcode indicating a delivery destination attached to a cardboard box transported from the packing process.

[0024] Furthermore, the molding process scheduling machine 5, which performs production planning on the manufacturing line, and the factory host computer 10, which controls all systems in the factory installed in the molding line factory, are bidirectionally connected. The factory host computer 10, the packaging management section 6, and the sorting management section 15 are each connected bidirectionally. In addition, packaging performance data is output from the packaging management section 6 to the sorting management section 15.

FIG. 2 shows a more specific configuration of the packaging management section 6.

In the figure, the packaging management section 6 includes a work-in-progress inventory management section 61, a standard information management section 62 that determines packing priorities, a packing progress management section 63, a packing plan creation section 64, a packing instruction management section 65, and It is composed of a cardboard inventory management section 66.

That is, the output of the data reading section 71 is led to the work-in-process inventory management section 61, and the output of the work-in-process inventory management section 61 is led to the packing plan creation section 64 and the cardboard inventory management section 66. It's dark.

The output of the standard information management unit 62 is also led to the packaging plan creation unit 64.
The output is led to the warehouse management section 13, the packing progress management section 63, and the packing instruction management section 65. Further, the output of the data reading section 72 is guided to the packing progress management section 63 as data indicating the packing performance.

Packing performance data from the packing instruction management unit 65 is output to the sorting management unit 15, and packing instructions from the packaging instruction management unit 65 are output to the terminal 8 installed at the work site, and the packing Print instructions from the instruction management section 65 are output to the printing machine 9.

Further, the shipping plan instruction from the packaging plan creation section 64 is output to the warehouse management section 13.
From 3 onwards, the record data of warehousing and retrieval is output to the work-in-process inventory management section 61.

FIG. 3 is a diagram schematically showing a manufacturing line to which the sorting management system of the present invention is applied.

That is, the conveying device 11 is loaded with a predetermined number (for example, 100 pieces) of molded products molded by the molding machine 1.
An ID tag, which is a recording medium 12, is attached to its side surface. The data recording unit 4 stores this recording medium (hereinafter referred to as an ID tag) 1 according to instructions from the molding group management unit 3.
2, the molding performance data for each transport unit is written.

The conveyance device 11 in which the molding performance data has been written in this way is then conveyed to the storage entrance of the storage warehouse 21, and is read by the data reading section 71 installed there.
The molding performance data written in the D tag 12 is read.

The read molding performance data is sent to the work-in-process inventory management section 61, and the work-in-process inventory management section 61 outputs a warehousing instruction to the warehouse line 22, and the warehouse line 22 is connected to the transport equipment. 11 into a storage warehouse 21 and stored at a predetermined position.

[0035] Furthermore, the transport equipment 11 that has been unloaded from the storage warehouse 21 according to instructions based on the shipping plan from the warehouse management department 13 is transported to the transport tip 221 of the warehouse line 22, where it collects molded products to be supplied to the packaging process. It is sent to the supply line 31. At this time, the conveyance tip 22 of the warehouse line 22
ID tag 12 by the data reading unit 72 installed in
The molding performance data written in is read and given to the packaging instruction management section 65 and the packaging progress management section 63 of the packaging management section 6.

Each molded product supplied to the molded product supply line 31 is conveyed to a position in front of a worker waiting on the packaging line 41. Further, the workers waiting on the packaging line 41 are supplied with cardboard boxes 52 on which data (barcodes) such as product number information are printed from the box supply line 51. is placed on the packing line 41, and the required number of molded products supplied from the molded product supply line 31 are stored therein, packed, and transported to a sorting process.

A bar code reading section 16 is provided on one side of the transport end of the packaging line 41, and a sorting device 17 is also installed, and each cardboard box 52 is
Immediately before being carried into the sorting device 17, necessary data is read by the barcode reading section 16 and provided to the sorting management section 15. The sorting management unit 15 outputs sorting instructions based on this data to the sorting device 17, and the sorting device 17 transfers each cardboard box 52 carried in according to the sorting instructions to a desired delivery destination line 81 of the delivery line 81.
Sorted into 1,812,813 etc. and supplied.

For example, a cardboard box 52 that has been given a sorting instruction to be delivered to company S1 is delivered to the delivery destination line 811, and a cardboard box 52 that has been given a sorting instruction to be delivered to company S2 is delivered to the delivery destination line 812. S to the next line 813
Cardboard box 52 with sorting instructions for delivery to three companies
It is designed to supply each.

Next, the operation of the manufacturing line including the sorting management system having the above configuration will be explained.

[0040] In the molding process scheduling machine 5,
For example, a daily, weekly, or monthly production process plan is created based on a sales plan, and the process plan data is a molding group that manages multiple molding machines 1 installed in the factory. Management department 3 and factory host computer 10
and is given to.

In the molding group management section 3, based on the process plan data from the molding process scheduling machine 5,
A molding instruction is sent to a molding machine control section 2 that controls each molding machine 1. The molding machine control section 2 molds each product according to this molding instruction. For example, when 100 products are molded using one molding machine 1, these 100 molded products are loaded onto a transport device (such as a transport container) 11, and the 100 molded products are
It is transported to the storage warehouse 21 for work-in-progress as a transport unit.

At this time, an ID tag 12 for data recording is attached to one side of the transport device 11, and the data recording section 4 attaches this ID tag 12 to the ID tag 12 according to instructions from the molding group management section 3. Corresponding molding performance data (e.g. product number,
Record the quantity, lot number, molding date and time, whether the product is handled as an express service, container identification number, etc.).

[0043] When the transport equipment 11 is transported to the warehouse line 22, the data reading unit 71 reads the molding performance data recorded on the ID tag 12 attached to the transport equipment 11, and reads this data. Work in process inventory management department 6
Send to 1. The work-in-progress inventory management section 61 sends this molding performance data to the packaging plan creation section 64 and the corrugated cardboard inventory management section 66.
give to.

In addition, the work-in-progress inventory management section 61 determines whether or not the sent molding performance data includes data indicating that it is treated as an express item, and if it is not treated as an expedited item, it issues a warehousing instruction to the warehouse line 22. Output. As a result, the transport device 11 is temporarily stored at a predetermined location within the storage warehouse 21. Additionally, if data indicating express handling is included, the work-in-process inventory management department 61
2, outputs an instruction to the effect that it is treated as a limited express. Based on this instruction, the warehouse line 22 transports the transported transport equipment 11 to the transport tip 221 of the warehouse line without storing it in the storage warehouse 21.

[0045] The work-in-process inventory management department 61 stores the warehouse line 22
The above judgment is made every time the transport equipment 11 is transported to the warehouse line 2.
It will be output to 2.

On the other hand, the packaging plan creation unit 64 sends a message to the warehouse management unit 13 based on the data indicating the packaging priority given from the standard information management unit 62 and the molding performance data from the work-in-process inventory management unit 61. Then, the shipping plan data of the transport equipment 11 is output. Based on this shipping plan data, the warehouse management section 13 takes out the corresponding conveying device 11, takes it out of the warehouse, and conveys it to the conveying tip section 221 of the warehouse line 22 when the shipping date and time arrive.

[0047] When the transport device 11 is transported to the transport tip portion 221, the data reading section 72 reads the transport device 11.
The molding performance data recorded on the ID tag 12 attached to the ID tag 12 is read, and the read data is provided to the packing instruction management section 65 and the packing progress management section 63. Thereafter, the transport device 11 carries out all of the loaded molded products to the molded product supply line 31 and is transported to the molding machine 1 again. The illustration of this transport means is omitted.

In the packing instruction management section 65, the data reading section 7
Based on the molding performance data given from 2, screw the cap into the molded product included in the molding performance data,
If the molded product requires post-processing such as attaching a sticker, a post-processing instruction is sent to the terminal 8, and the terminal 8 displays a message to that effect on the display. Then, the waiting workers are made to prepare for post-processing.

The packing instruction management unit 65 also outputs packaging performance data based on the molding performance data to the sorting management unit 15 for the next process.

The packaging instruction management unit 65 also sends a printing instruction to the printing machine 9, based on the molding performance data, including a quantity instruction such as how many corrugated cardboard boxes 52 for packaging, which are auxiliary materials, should be prepared. For example, one cardboard box 52
If there are 10 molded products in the box, 10 cardboard boxes5
Instruct them to prepare 2. As a result, the printing machine 9
Ten cardboard boxes 52 are set in the box.

Based on this printing instruction, the printing machine 9 prints the product number information on the surface of the cardboard box 52 set in the ITF.
and JAN code barcodes.

The cardboard boxes 52 on which the product number information has been printed in this way are assembled manually by a worker (not shown) (or automatically assembled by an assembly machine (not shown)), and then supplied to the box supply line 51. Packing line 4
It is transported to the worker who is waiting at 1.

[0053] Then, the worker waiting on the packaging line 41, in accordance with the work instruction data displayed on the terminal 8, places the cardboard box 52 supplied by the box supply line 51 on the molded product supply line 31. A predetermined number of molded products (in this case, 10) are stored, and then packed (or automatically packed by a packing machine (not shown)), and passed on a packing line 41 to a sorting device 17. Transport to.

In the sorting management section 15, the packing instruction management section 6
5 and the sorting and shipping plan data output from the factory host computer 10 are input, and the sorting process of the packaged products is performed based on the packing record data according to a preset sorting pattern. The sorting device 17 sends sorting instructions based on the sorting process.
Output to.

That is, when the sorting management section 15 is given the packing performance data from the packing instruction management section 65, it searches the contents of the sorting/shipping plan data given from the factory host computer 10, and performs the sorting/shipping of the corresponding location. Read shipping plan data. Then, this sorting and
Based on the shipping plan data and the packing performance data given from the packing instruction management section 65, the sorting/shipping plan quantity is divided into transport units and set according to an internally set sorting pattern.

A more specific operation of the sorting management section 15 will be explained.

[0057] The sorting management unit 15 has, for example, (1) a pattern for sorting based on ratio allocation priority, (2) a pattern for sorting according to a preset shipping priority order, and (3) a combination of a proportional allocation priority pattern and a shipping priority pattern. Three composite patterns are set in advance, and the sorting management section 15 selects any one of these three patterns to perform the sorting process.

[0058] Below, among these three patterns, (1)
The pattern (3) and the pattern (3) will be explained. However, the delivery destinations (sorting destinations) are set to three locations S1, S2, and S3, and an example of sorting/shipping plan data given from the factory host computer 10 is shown in FIG. 4, and an example of packing performance data given from the packing instruction management section 65 is shown in FIG. Note that the numerical values shown in FIGS. 4 and 5 are per packaged product (corrugated cardboard box).

(1) When a sorting pattern is selected that prioritizes ratio allocation.

In this case, in the sorting/shipping plan, S1=
20 pieces, S2 = 30 pieces, S3 = 50 pieces, a total of 100 pieces are required, but the actual packing result is 40 pieces.

Therefore, the sorting management section 15 performs the following calculation to determine the number of sorting items to each sorting destination.

[0062]

[Equation 1] Number of sorting in S1 = 40 x [20/(20+30+5
0)]=8

[0063]

[Math 2] Number of sorting in S2 = 40 x [30/(20+30+5
0)]=12

[0064]

[Math 3] Number of sorting in S3 = 40 x [50/(20+30+5
0)]=20

On the other hand, a barcode (IFT, JAN code, etc.) corresponding to the product number printed on the cardboard box 52 is read by the barcode reading section 16, and the read information is sent to the sorting management section 15.

The sorting management section 15 outputs a sorting instruction to the sorting device 17 according to this information and the number of sorting obtained by calculation, and the sorting device 17 performs automatic sorting according to this sorting instruction. In other words, the first eight pieces are supplied to one delivery destination line 811 of the delivery line 81,
The next 12 pieces are supplied to the next delivery destination line 812, and the next 20 pieces are supplied to the next delivery destination line 813.

After that, the sorting/shipping plan data is deleted by the transport unit and corrected to the quantity data shown in FIG.

[0068] If the next packing record is 30,
The sorting management unit 15 performs the following calculations to determine the number of sorting items to each sorting destination based on the packing record.

[0069]

[Math. 4] Number of sorting in S1 = 30×[12/(12+18+3
0)]=6

[0070]

[Math. 5] Number of sorting in S2 = 30×[18/(12+18+3
0)]=9

[0071]

[Equation 6] Number of sorting in S3 = 30 x [30/(12+18+3
0)]=15

[0072] If production were to stop for some reason, the actual number of shipments at that point would be 70 (=40+30) for the planned shipment of 100, but in this case, S1 = 14 (8 + 6), S2=21
(12+9), S3=35 (20+15) have already been sorted, and the distribution ratio of 2:3:5 has been achieved.

Although not shown, the cardboard boxes 52 supplied to each delivery line are sequentially loaded onto the pallets installed on each delivery line until they are full (or until a predetermined quantity is reached). .) After being loaded, they are palletized at a designated location in the storage area.

(2) When a composite pattern is selected, which is a combination of a proportional allocation priority pattern and a shipping priority pattern.

[0075] Here, the sorting destination S1 has the highest priority for shipping,
It is assumed that sorting destination S2 and sorting destination S3 are proportionate.

[0076] In this case, the number of sorts for the packing record 40 is first sorted by destination S1=20, and the remaining 20 sorts become the ratio distribution. Therefore, the sorting management unit 15 performs the following calculation to determine the number of sorting items to each sorting destination.

[0077]

[Equation 7] Number of sorting in S2 = (40-20) x [30/(30
+50)]≒8

[0078]

[Equation 8] Number of sorting in S3 = 40-20-8 = 12

00
[79] On the other hand, the barcode reading section 16 reads the barcode (IFT, JAN code, etc.) corresponding to the product number printed on the cardboard box 52, and sends the read information to the sorting management section 15.

The sorting management section 15 outputs a sorting instruction to the sorting device 17 according to this information and the number of sortings determined by calculation, and the sorting device 17 performs automatic sorting according to this sorting instruction. In other words, the first 20 pieces are supplied to one delivery line 811 of the delivery line 81, the next 8 pieces are supplied to the next delivery line 812, and the next 12 pieces are supplied to the next delivery line 812. 813.

[0081] After that, the sorting/shipping plan data is deleted by the transport unit and corrected to the quantity data shown in FIG.

[0082] If the next packing record is 30,
The sorting management unit 15 performs the following calculations to determine the number of sorting items to each sorting destination based on the packing record.

[0083]

[Equation 9] Number of sorting in S2 = 30 x [22/(22+38)]
=11

[0084]

[Formula 10] Number of sorting in S3 = 30-11 = 19

008
5] If production were to stop for some reason, the number of shipments planned at that time would be 70 (
=40+30), but at this time S
1=20, S2=19(=8+11), S3=31(=
12+19) have already been sorted, and moreover, all S1 and the S2:S3 distribution ratio of 3.06:5 have been achieved.

[0086] In the above embodiment, an ID tag capable of writing and reading data using microwave radio waves is used as the recording medium 12. However, as an alternative to this, for example, a bar It is possible to use a tag using a code, an IC card, a magnetic card, or the like.

[0087]

[Effects of the Invention] The production line sorting management system according to the present invention is configured to sort on a performance basis according to a certain sorting pattern when the sorting/shipping plan differs from the packing performance data. This enables speedy and flexible sorting to suit the on-site situation, such as when sorting by . It also has the effect of allowing accurate results to be grasped in real time.

[Brief explanation of the drawing]

FIG. 1 is a block diagram showing the electrical configuration of a manufacturing line including a sorting management system according to the present invention.

FIG. 2 is a block diagram showing a more specific configuration of the packaging management section.

FIG. 3 is a diagram schematically showing a production line to which the sorting management system of the present invention is applied.

FIG. 4 is a table showing the file status of sorting/shipping plan data.

FIG. 5 is a table showing the file status of packing record data.

FIG. 6 is a table showing the file status of sorting/shipping plan data after correction.

FIG. 7 is a table showing the file status of sorting/shipping plan data after correction.

[Explanation of symbols]

1 Molding machine 3 Molding group management section 4 Data recording section 5 Molding process scheduling machine 6 Post-processing
Packaging management section 7 Data reading section 10 Factory host computer 11 Transport equipment 12 Recording medium (ID tag) 13 Warehouse management section 15 Sorting management section 16 Barcode reading section 17 Sorting device

Claims (1)

[Claims] [Claim 1] A production line planned in advance that includes a packaging process for packaging products transported from the manufacturing process and a sorting process for sorting each packaged product packed in a cardboard box in this packaging process. a factory host computer that creates a sorting and shipping plan based on process plan data; a packaging management department that issues packaging instructions based on molding performance data sent from the manufacturing process and outputs the packaging performance data; The packing record data output from the packaging management department and the sorting/shipping plan data output from the factory host computer are input, and the packaged items are sorted based on the packing record data according to a preset sorting pattern. and a sorting management unit that outputs sorting instructions based on the sorting process, and a sorting device that sorts the transported packaged items according to the sorting instructions output from the sorting management unit. Line sorting management system.