JPH04346105A - Process control system for molding line - Google Patents

Abstract

PURPOSE:To offer the process control system for the molding line which can output operation indications conforming to the actual conveyance order of moldings even if the conveyance order of moldings is different from a process planning by putting the moldings and molding result data together. CONSTITUTION:This system is equipped with a molding group control part 3 which controls the molding of plural molding machines 1 installed in the molding line, a recording medium 12 which is stuck on conveyance equipment 11 and enables the molding result data to be written and read, and a data recording part 4 which records the molding result data on the recording medium 12 stuck on the conveyance equipment 11, item by item, according to indications from the molding group control part 3. Further, the system is equipped with a machining and packing control part 6 which controls a machining and a packing process and a data read part 7 which reads the molding result data out of the recording medium 12 stuck on the conveyance equipment 11.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to a molding process using a molding machine, a transport process in which molded products molded in this molding process are loaded onto a transport device and transported in units of a predetermined number of transport units, and this transport The present invention relates to a process control system for a molding line that includes a post-processing/packing process in which a predetermined number of molded products transported through the process are subjected to post-processing and then packed.

0002

2. Description of the Related Art Conventionally, various management systems have been proposed for such molding lines and assembly lines in order to increase their production efficiency.

[0003] For example, there is a so-called "take-back method" in which the post-process picks up the necessary parts when needed to the pre-process, and the pre-process produces as many parts as are picked up.
There is also the so-called "Kanban system" in which production is carried out by using orders from later processes as production instructions for earlier processes [Dictionary for a thorough understanding of the Toyota Production System (published by Nikkan Kogyo Shimbun)].

0004

[Problems to be Solved by the Invention] To explain more specifically, for example, in the current process (2), a semi-finished product (a) produced by the processing in the previous process (1) is processed to produce a semi-finished product (b).
Suppose you want to make .

In this case, since a wide variety of products are processed in the previous step (1), the semi-finished products (a) are processed in batches of a certain amount.

[0006] Here, even if an instruction to create the semi-finished product (a) is output from the current process (post-process (2)) to the pre-process (1), depending on the process plan of the pre-process (1), In some cases, it may not be possible to produce the semi-finished product (a) at the same time, and time is required to process each lot, resulting in a certain interval.

Therefore, in order to be able to produce the semi-finished product (b) at any time in the post-process (2), it is necessary to
), there is a problem in that it is necessary to keep a certain amount of semi-finished products (a) in stock.

[0008]Although there are management systems as described above, in a molding line equipped with multiple molding machines, each process is actually managed manually, so
The lead time from molding to shipping varied depending on the product, which was a contributing factor to delivery delays.

[0009] Therefore, the molding performance data actually formed in the molding process is sent to the next process management department via communication, and the next process management department issues subsequent work instructions based on the sent molding performance data. A system of doing so is also conceivable.

However, with this system, there is no problem as long as the order of molding performance data sent via communication matches the order of molded products actually sent, but in the actual field, there is no problem. In some cases, molded products that were molded at almost the same time are sent in different orders, or are transported manually, and the order of the transported products does not necessarily match the order of the molding performance data. Problems arise such as inability to manage work instructions.

The present invention was made in view of the above circumstances, and its purpose is to integrate the transportation of molded products and the transmission of molding performance data (here, this is done by attaching it to a transportation device). Therefore, it is an object of the present invention to provide a process control system for a molding line that can output work instructions in accordance with the actual transport order of molded products even if the transport order of molded products differs from the process plan.

0012

[Means for Solving the Problems] In order to solve the above problems, a process control system for a molding line according to the present invention includes a molding process using a molding machine, and a transportation unit of a predetermined number of molded products molded in this molding process. In a molding line equipped with a transport process in which each molded product is loaded onto a transport device and transported in bulk, and a post-processing/packing process in which a predetermined number of molded products transported through this transport process are subjected to post-processing and then packed. ,
a molding group management unit that manages molding by a plurality of molding machines installed on a molding line; a recording medium that is attached to the conveyance equipment and is capable of writing and reading molding performance data; a data recording unit that records molding performance data for each molded item on a recording medium attached to the transport equipment in accordance with instructions from the transport unit; and a post-processing unit that manages the post-processing and packaging processes.・Equipped with a packaging management department and a data reading section that reads molding performance data recorded on a recording medium attached to the transport equipment according to instructions from the post-processing and packaging management department,
The packaging management section is configured to issue subsequent work instructions based on the molding performance data read by the data reading section.

[0013]

[Operation] The molding group management section manages molding of a plurality of molding machines, grasps the molding results for each molded item, and instructs the data recording section to write the grasped molding performance data. In response to a write instruction from the molding group management section, the data recording section writes corresponding molding performance data onto a recording medium attached to a conveying device loaded with a predetermined number of molded products.

[0014] Here, as the recording medium, an ID tag is used, in which data can be written to the internal memory using, for example, microwave radio waves, and the written data can also be read. Further, the data recording section uses a controller equipped with an antenna unit that transmits and receives microwave band radio waves that can write data to the ID tag.

[0015] The conveying device is conveyed to the post-processing/packing process together with the recording medium on which the molding performance data is recorded.

The post-processing/packaging management section instructs the data reading section to read. The data reading section reads the molding performance data recorded on the recording medium attached to the conveyance equipment that has been transported in response to reading instructions from the post-processing and packaging management department, and sends it to the post-processing and packaging management department. .

[0017] Here, the data reading section uses a controller equipped with an antenna unit that transmits and receives microwave band radio waves that can read data written on an ID tag, which is a recording medium.

The post-processing/packaging management section issues post-processing instructions, packaging instructions, printing instructions, etc. based on the molding performance data given from the data reading section. That is, if there is a molded product that requires post-processing such as screwing in a cap or attaching a seal, these instructions are given to the post-processing/packaging process. In addition, instructions for carrying out the cardboard box for packaging, printing instructions on the cardboard box (for example, printing a bar code to distinguish the delivery destination), etc. are given to the post-processing/packing process.

[0019] In other words, since the system is such that the molded product and information (molding performance data) for each transport unit from the molding process through the transport process to the post-processing and packaging process flow together on the molding line, Flexible work instructions tailored to the actual situation on site enable speedy and lean work.

[0020]

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 molding line including a process control system according to the present invention.

In the molding line of this embodiment, molding is performed 24 hours a day using FMS equipment, while the post-processing and packaging processes are performed manually by workers only during the day shift, and the molded products are transported in a certain transport unit (for example, It is assumed that the structure is such that the parts are transported to the next process in units of 100 pieces.

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.

[0024] Also, the post-processing/packing management department 6, which manages the post-processing/packing process, sends instructions for preparing auxiliary materials, post-processing and packaging instructions, etc. to the terminal 8 installed in the post-processing/packing process. At the same time, an instruction to print on the cardboard box is sent to the printing machine 9. In addition, the post-processing/packaging management department 6 also has a transport device 11 loaded with a predetermined number of molded products and transported.
The output of a data reading section 7 that reads molding performance data from a recording medium 12 attached to the recording medium 12 is connected. Furthermore, the post-processing/packaging management section 6 is bidirectionally connected to a warehouse management section 13 that manages a storage process in which work-in-process products are temporarily stored in a warehouse.

[0025] Furthermore, the molding process scheduling machine 5, which performs production planning on the molding line, and the factory host computer 10, which controls all systems in the factory installed in the molding line factory, are bidirectionally connected. The molding group management section 3, the molding process scheduling machine 5, and the factory host computer 10, and the post-processing/packaging management department 6, the molding process scheduling machine 5, and the factory host computer 10 are each bidirectionally connected. . That is, a communication network is formed around the factory host computer 10 between the molding group management section 3, the molding process scheduling machine 5, and the post-processing/packing management section 6, and the system performs molding with priority given to shipping order. It becomes.

FIG. 2 shows a more specific configuration of the post-processing/packaging management section 6.

In the figure, the post-processing/packaging management department 6 is
Work-in-progress inventory management department 61, standard information management department 62 that determines packaging priorities, packaging progress management department 63, and packaging plan creation department 6
4. It is composed of a packing instruction management section 65 and 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 led to the packaging plan creation unit 64, and the output of the packaging plan creation unit 64 is sent to the warehouse management unit 13, the packaging progress management unit 63, and the packaging instruction management unit 65. guided by. The warehouse management department 13 receives shipping plan instructions from the packaging plan creation department 64, and the warehouse management department 13 outputs the actual data of warehousing and shipping to the work-in-process inventory management department 61. It has become.

Furthermore, the output of the data reading section 72 is led to the packing progress management section 63 and the packing instruction management section 65 as data indicating the packing performance.

Packing instructions from the packing instruction management section 65 are output to the terminal 8 installed at the work site, and printing instructions from the packing instruction management section 65 are output to the printing machine 9. ing.

FIG. 3 is a diagram schematically showing a molding line to which the process control 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 formed 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. This 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 stores the transport equipment 11. It is stored in the warehouse 21 and stored at a predetermined position.

[0035] Furthermore, the transport equipment 11 that has been taken out of 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 is supplied to the post-processing and packaging process. The molded product is sent to the molded product supply line 31. At this time, the data reading unit 72 installed at the transport tip 221 of the warehouse line
The molding performance data written in the tag 12 is read,
The information is given to the packing instruction management section 65 and the packing progress management section 63 of the post-processing/packing 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 worker waiting on the packaging line 41 is supplied with a cardboard box 52 on which the necessary data is printed from the box supply line 51, and the worker can fill the cardboard box 52 with the required number of molded products. It will be stored, packed, and transported to the next process.

Next, the operation of the process control system having the above configuration will be explained.

[0038] 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.).

[0041] When the transport equipment 11 is transported to the warehouse line 22, the data reading section 71 reads the molding performance data recorded on the ID tag 12 attached to the transport equipment 11. 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 unit 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.

[0043] 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.

When the transport device 11 is transported to the transport tip 221, the data reading unit 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 packaging instruction management unit 65 also sends a printing instruction to the printing machine 9 as to how many corrugated cardboard boxes 52 for packaging, which are auxiliary materials, to be prepared, based on the molding performance data. For example, if 10 molded products are placed in one cardboard box 52, an instruction is issued to prepare 10 cardboard boxes 52. As a result, ten cardboard boxes 52 are set on the printing machine 9.

In addition to printing instructions from the packaging instruction management section 65, the printing machine 9 is also given sorting instructions based on molding performance data, and the printing machine 9 performs sorting instructions based on these sorting instructions and printing instructions. , A bar code indicating the delivery destination is printed on the surface of the set cardboard box 52. That is, if all the data in the sorting instructions specify the same delivery destination, the barcode of the specified delivery destination is printed on all ten cardboard boxes 52. Furthermore, if the sorting instruction data indicates three items for delivery destination A and the remaining seven items for delivery destination B, barcodes for the corresponding delivery destinations are printed. Further, the printing machine 9 receives the product name, product number, size, color, quantity, and lot number according to the printing instructions from the packaging instruction management section 65.
, product illustrations, company name, product classification name, etc. are also included in the cardboard box 52
print on the surface of As the printing method, a thermal transfer method using a moving printer head is suitable.

The cardboard boxes 52 with the delivery destination printed in this manner 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 41
The machine is transported to the worker who is waiting.

[0050] Then, the worker waiting on the packaging line 41 follows the work instruction data displayed on the terminal 8 and 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, then packed (or automatically packed by a packing machine (not shown)), and transported to a sorting device (not shown). .

[0051] In this manner, the process control system of the present invention transfers the molding performance data of the previous process (molding process) to the next process (storage process and post-processing/packing process) together with the molded product. Because the data and molded product always match when planning work instructions, it is possible to give work instructions that match the on-site situation.

[0052] 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.

[0053]

Effects of the Invention: The process control system for a molding line according to the present invention is configured so that molded products and molding performance data are integrated and moved through each process. Since the actual molding data always matches the actual molded product, work instructions can be given without wasting time. In other words, since the printing instructions on the cardboard boxes are given based on actual molding results, there is no need to prepare printed cardboard boxes in advance, which greatly reduces production lead time, as well as shortens delivery times. This achieves various effects such as preventing stockouts and reducing inventory.

[Brief explanation of the drawing]

FIG. 1 is a block diagram showing the electrical configuration of a molding line including a process control system according to the present invention.

FIG. 2 is a block diagram showing a more specific configuration of the post-processing/packaging management department.

FIG. 3 is a diagram schematically showing a molding line to which the process control system of the present invention is applied.

[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 department 7 Data reading department 10 Factory host computer 11 Transport equipment 12 Recording medium (ID tag) 13 Warehouse management department

Claims (1)

[Claims] [Claim 1] A molding process using a molding machine, a transport process in which the molded products molded in this molding process are loaded onto a transport device in units of a predetermined number of transport units, and transported by this transport process. In a molding line equipped with a post-processing/packing process in which a predetermined number of molded products are subjected to post-processing and then packed, a molding group management department that manages molding by a plurality of molding machines installed on the molding line; A recording medium is attached to the conveying device and is capable of writing and reading molding performance data, and a recording medium is attached to the conveying device, and the molding results for each molded item are recorded on the recording medium attached to the conveying device according to instructions from the molding group management department. A data recording section records data for each transport unit of the molded product; a post-processing/packing management department manages the post-processing/packing process; and a data reading unit that reads molding performance data recorded on the attached recording medium, and the post-processing/packaging management unit issues subsequent work instructions based on the molding performance data read by the data reading unit. A process control system for molding lines that is characterized by: