JPH0471004A - Production control system - Google Patents

Abstract

PURPOSE:To construct an efficient automation line system and to obtain a production control system by allowing a master controller to collectively control files for analyzing and aggregating the working contents and respective lines of a worked target. CONSTITUTION:The working contents of respective bodies 6 on a production line 5 are set up to a machine sort or the like by a host computer 1 in each prescribed number of bodies and the set information is transmitted to line area computers 2A, 2B through a personal computer network 3A. On the other hand, conversion files divided in each working process of the line 5 are formed by a derived aggregation maintenance computers 2C, 2D, 2E and transmitted to the host computer 1. Working commands corresponding to the working contents of respectively different machine sorts or the like are analyzed and aggregated by the computers 2A, 2B and outputted to respective sequencers 4A to 4X in each line and prescribed working corresponding to each machine sort, each derivation, or the like is executed in each line.

Description

Detailed Description of the Invention "Industrial Application Field J The present invention is used, for example, in an automobile production line that produces a mixture of different models, and uses a network to distribute processing content information and This invention relates to a production management system that instructs and executes processing such as welding for each model and number of machines.

"Prior Art" In a production line or the like, processing machines are placed at predetermined positions and perform various processing on workpieces moving along the line. By the way, like a car production line,
When producing different types of cars on the same line, each processing machine must perform processing according to the type of car. Also,
The processing order information must also be converted into a model pattern for processing according to the vehicle model of each processing machine. Furthermore, since the processing order information is miscellaneous and complicated, it is necessary to organize and consolidate the information for each processing machine.

For this reason, operators in conventional machining processes first organize and aggregate machining order information into rank data for each machining process, as shown in the order of the processes in Figure 6. The data is converted into a machine type pattern, the machine type pattern is input into the processing machine, and the workpiece is set in the processing machine based on the ranking data.

These are conversion processes 1 and 2 performed by humans. The ranking data includes model (model year, manufacturing plant, 2-door, 4-door, etc.), derivation (grade), obunjin (with or without a sunroof, etc.), rod number (number given to each predetermined number of vehicles), and predetermined number. It includes numerical values such as the number of machines, and is arranged based on processing order. On the other hand, the processing machine is placed within the production line area, and when the machine model pattern is input by the operator, it creates a code to determine the operation using the conversion table stored internally, and according to this code. Perform processing. This is the third conversion process using (M/C). The code includes the processing jig number and operation pattern, the robot job number (operation pattern, welding condition number, etc.), and the like.

For example, in a processing step of welding a side panel to a floor panel, processing order information is converted into order data for the processing step, further converted into a model pattern, and then input into a processing machine. Then, based on the ranking data, the model,
The sight panel that matches the derivation etc. is taken out from the mounting location and set on the jig.Meanwhile, the processing machine creates a code to determine the operation based on the machine model pattern and sets it on the floor.
Weld the necessary parts to the panels and assemble the floor panel and side panels.

In addition, the work of converting the ranking information into a model pattern by aggregating the ranking data into processing process units will not be subject to change in the event of a car model change, etc. provide education. Further, when the processing information is changed due to an order from a user, reprocessing, etc., the changed ranking information is transmitted to the processing process each time.

``Problem to be solved by the invention'' However, in such conventional production lines, operators (people) convert and aggregate the processing ranking table in each processing process arranged in the line area. Save,
There were problems in that human errors occurred, production management was inefficient, and even though it was an automated line, the number of man-hours increased.

In addition, the aggregation and conversion work of the processing ranking table is performed as the number of models to be produced increases. It becomes complicated, the number of man-hours increases, and the efficiency of production management is poor.

Furthermore, the content of the task of aggregating and converting ranking information changes due to model changes of car models, etc., but in automobile lines that produce different models, model changes of car models are complicated, so each time there is a change. The number of man-hours required for training the operators increases, and the efficiency of production management deteriorates. Furthermore, ranking information may be changed based on orders received from users, reprocessing, etc.
Changes are made, but due to factors such as shortening of manufacturing lead times in recent years, ranking information has become more frequently changed. At this time, it is necessary to transmit the changes in the ranking information to each process every time there is a change, which makes the overall production management flow unsmooth and reduces efficiency.

Therefore, the present invention makes it possible to reduce the number of man-hours required for operators, and also to realize the construction of an efficient automated line system without increasing the burden on operators even if the number of manufactured models increases, thereby increasing the efficiency of production management. The purpose is to provide a production management system that can increase the production efficiency.

"Means for Solving the Problems" In order to achieve the above objectives, the production management system according to the present invention:
As the basic conceptual diagram is shown in Figure 1, there is a production line b, which transports workpieces including different types from the input section to the delivery section between processing steps in a predetermined order and in a predetermined number. a higher-level controller C that sets and stores processing details for each machine type, derivation, etc. for each workpiece a on the workpiece b for each predetermined number of machines, and distributes information on the processing details using a network; Processing order information on production line b
A middle-level controller d creates a conversion file that divides into model derivation classifications for each machining process, and distributes the conversion file to a higher-level controller C, and a middle-level controller d sends processing order information and the conversion file from the higher-level controller C. a lower controller e that receives the processing order information, converts and aggregates the processing order information into processing instruction information for each processing step based on the conversion file, and provides processing instructions corresponding to the processing contents of the workpiece for each line; and a production line. Processing execution in which a predetermined process corresponding to each model derivation, etc. is performed on a predetermined number of workpieces a, arranged in area b, on each line in that order, based on processing instructions from a lower-level controller e. It is characterized by comprising means f.

Further, as a preferable aspect, the lower controller e
is a file for converting and aggregating processing information for each line distributed from the upper controller C, and contains the settings of the derived aggregation code for each model for each line, the option code settings for each line, and the settings for each line. It is characterized in that it includes at least one of the following: a separate M/C operation pattern code setting, a workpiece material code setting for each line, and a representative value setting for an aggregate code for each line.

1 action" In the present invention, the upper controller C controls the workpiece λ
For each predetermined number of machines, processing details are set for each model, each derivation, etc., and this information is distributed to a plurality of lower-level controllers e using a network. In addition, a conversion file is created by the middle-level controller d to classify it into model derivation categories for each machining process, and this conversion file is distributed to the high-level controller C. Then, the lower controller e analyzes and aggregates the machining instructions for the machining order for each different model, each different type, etc., and the machining execution means f for each line.
is given, and predetermined processing corresponding to each line, model, derivation, etc. is executed.

Therefore, files for analyzing and aggregating processing details and lines for the workpieces are collectively managed by the higher-level controller C, reducing man-hours for inputting or changing processing order and file data. By aggregating processing information for each line by the lower-level controller e, data management efficiency is increased, processing efficiency is greatly improved, and production management efficiency is improved.

"Example" Hereinafter, the present invention will be explained based on the drawings.

2 to 5 are diagrams showing an embodiment of the production management system according to the present invention.

First, the configuration will be explained. FIG. 2 is a schematic configuration diagram showing a network in the welding department of an automobile production line to which the present invention is applied. In this figure, l is a host computer (upper controller) as a processing order file computer, 2C, 2D, and 2E are derived aggregation maintenance computers (middle level controllers), 2A, 2B
is a line area computer (lower controller),
3.3A is a network, for example, in 3, there are a total of 44 nodes, and in 3A, there are 6 communication terminals.
It has individuality. 4A to 4X are terminal controllers (processing execution means), which are composed of welding robots that execute welding processing. Reference numeral 5 denotes a production line, in which bodies (workpieces) 6 including different models are placed on transport carts (not shown) and transported in a predetermined order every predetermined number from the input section to the delivery section. The production line 5 includes a large number of lines 203 to 21 for each welding process, as shown in FIG. 5, which will be described later.
2 is provided, and processing information is aggregated for each line.

The host computer 1 receives, for example, weekly machining rank data from the external computer IA, checks the seams of the machining rank data, stores the data, distributes the machining rank data to the line area computers 2A and 2B, and performs processing for each line. Deliver files to aggregate information. That is, for each body 6 on the production line 5, the processing order is set and stored for each predetermined number of units, model derivation, etc., and after a conversion file for unforeseen aggregation is distributed using the network 3, the processing order is set and stored. Distribute processing order information. The processing information aggregation settings for each line include, for example, the setting of a derived aggregation code for each model for each line, the setting of an option code for each line, the setting of an M/C operation pattern code for each line, and the setting of an M/C operation pattern code for each line. Set the workpiece material code, set the representative value of the aggregate code for each line, etc. The derivation aggregation code by model is 1. In order to identify differences in car models and to indicate 2-door, 4-door, foreign, domestic, etc., codes with large digits are used.On the other hand, on the line, the same processing may be performed even if the car model is different. The model-specific derived aggregation code has been simplified to the point where it can be used on-line.

A predetermined number of bodies 6 are arranged in a predetermined order on the production line 5, and processing details for each body 6 are determined, for example, on a weekly basis and loaded into the host computer 1 in advance. Further, the information of the host computer 1 is transferred via the personal computer network 3A to 2E, which is one of the derived central maintenance computers, in a state of constant communication, thereby backing up the data.

That is, 2E, which is one of the derived central maintenance computers, stores data and has an alternative function. Further, the switching device 10 performs switching with an alternative device. Also,
The derivation aggregation maintenance computers 2C, 2D, and 2E create a conversion file that classifies the processing order information into model derivation classifications for each process of the production line 5, and distributes the conversion file to the host computer l. Furthermore, the conversion file distributed to the host computer 1 is transferred to one of the derivative aggregation maintenance computers that are in constant communication.
Back is performed at the same level by 2E. That is, the host computer 2 stores data as a file server function, and the 2E, which is one of the derived integrated maintenance computers, stores the data of the host computer 1 at the same level as an alternative function. In addition, line area computer 2 for 2C and 2D among the derived integrated maintenance computers
As an alternative function to A and 2B, it has a function of converting processing order information to processing instruction information, which will be described later. That is, 2C of the derived aggregate maintenance computers
, 2D, line area computers 2A, 2
B, and after processing order information is distributed from the host computer I, it satisfies the function as a line area computer. The host computer l has a disk drive device 11 and a printer 1 as attached devices.
2, a keyboard 13 and a CRT display 14, and this is the same for the other derivative integrated maintenance computer 2E (however, the others are not shown).
.

The information from the derived aggregation maintenance computers 2C and 2D is once stored in the host computer 1 and then sent to the line area computers 2A and 2 via the network 3A.
These computers receive the processing order information and the conversion file from the host computer 1, convert the processing order information into processing instruction information for each processing step based on the conversion file, and process each body 6. Processing instructions corresponding to processing contents for each different model, each different derivative, etc., are output to the sequencers 4A to 4X via the network 3 for each line. The derived integrated maintenance computer 2C includes a disk drive device 21, a printer 22,
It has a keyboard 23 and a CRT display 24, which is similar to other derived central maintenance computers 2.
The same applies to D and line area computers 2A and 2B (however, the others are not shown). Note that 25 is a transceiver for the PC network 26, and the reference numerals are omitted for other transceivers to avoid complexity.

The sequencers 4A to 4X are arranged within the area of the production line 5, and are connected to a line area computer 2A.

Based on the processing instructions from 2B, a predetermined welding process corresponding to each model derivation is performed on each line of a predetermined number of bodies 6 in the order in which they are arranged.

Here, the network of the above processing instruction system is shown in FIG. 3 in an easy-to-understand manner. In the figure, IA is an external computer that performs information processing such as creating weekly processing ranking data, l is a processing ranking file computer serving as a host computer, and 2C.

2D, 2E are derived central maintenance computers, 2A
, 2B is a line area computer, 2G is a performance monitor computer, 2H is a performance data collection controller, 4
A to 4X are M/C controllers as sequencers.

31 to 35 are performance monitor computers, which are placed in, for example, an office, a maintenance department, a planning room, a shipping room, etc.
Display machining results in real time. The performance monitor computer 31 is the main body 41. Printer 42, keyboard 43
and a CRT display 44, and this is the same for other performance monitor computers (however, the other numbers are omitted). 51 is a line server in the network 3, and 52 is a power supply device.

The information handled by the network 3 includes the following information.

■Processing instructions ■Actual number of machines processed ■Line stop time ■Line takt: processing time per unit number ■Flow between lines/Relationship between the cumulative number of machines in the own process and the cumulative number of machines in the next process.

■Line automatic operation signals Including channel, manual, and abnormal signals.

■Maintenance communication signal ■Engineer communication signal ■Line status signal Next, the operation of this embodiment with the above configuration will be explained.

In the production process that involves welding, first the external computer IA
For example, processing contents (in particular, processing order) for the body 6 are determined and sent to the host computer 1 on a weekly basis, and are loaded into the host computer 1 in advance. This information is stored for each body 6 on the production line 5.
The machining order is set and supplemented for each predetermined number of machines and each model.
It is distributed to the line area computers 2A and 2B via the personal computer network 3A. In addition, some of the information includes, for example, the model of body 6 (body model name, 4 doors, 2
(door type, etc.), derived information (destination country, destination/cold region, etc.)
, option information (sunroof presence/absence, etc.).

These correspond to, for example, model-specific derived aggregation codes for each line, open-yong codes for each line, and the like.

In addition, the setting of derivation aggregation codes for each model for each line is performed by the derivation aggregation maintenance computers 2C12D and 2E, and in particular, information on machining order is stored as a conversion file that divides the production line 5 into model derivation classifications for each machining process. This conversion file is created on host computer 1.
It is distributed to the host computer 1 as setting data, and is further distributed to the line area computers 2A and 2B.
will be delivered to.

Next, the line area computer 2A12B analyzes the machining order information from the host computer 1 using the conversion file, and provides machining instructions corresponding to the machining contents for each body 6, such as for each different model, to the sequencer 4 for each line.
Output to A to 4X. On the other hand, on the production line 5, bodies 6 including different models are placed on transport vehicles from the input section to the output section, and are transported between processing steps in a predetermined order and in predetermined numbers. . Then, based on the processing instructions summarized for each line, the sequencer 4
A predetermined number of bodies 6 placed on the production line 5 by A to 4X are subjected to a predetermined welding process corresponding to each model, each derivation, etc. in the order in which they are lined up.

Here, the processing of the derived aggregated data management system is performed, for example, as follows.

In the derived aggregate code setting process, the derived aggregate code is set for each node (line), and model pattern data and model pattern representative are automatically set when a new derived aggregate code is input based on the screen of the computer performing this process. Data is created. In the model pattern display representative selection process, model pattern data is displayed and its representative setting is performed, and there is only one representative within the same model pattern. In the option code name setting process, an option instruction code corresponding to the option code and an obon name corresponding to the option instruction code are set. In the M/C model pattern setting process, the M/C model pattern in the derived aggregate code that corresponds to the M/C model pattern on the field operation side is set. In the conversion table transmission process, after each conversion file of the derived aggregation file, model pattern file, model pattern conversion file, M/C model pattern conversion file, Obunyon code file, and Obunyon name file is sent to the line area computer, the network 3
Send the necessary data to other computers and sequencers on the computer. In the online display process, the transmission status is displayed online on the conversion table transmission process screen.

Figure 4 shows a specific example of welding process, step 101-
Assembly of the rear frame, rear floor panel, front wheel house, front floor, rear floor, and front combination with 106 (components: COMF)
The rear floor is inspected in step 107, and the rear floor is inspected in step 108.
At +09, the rear floor, front floor, and front combination were each carried out. In step 110, the parts assembled so far are transported, and in step 111, the floor is assembled.

Next, in step 112, submain general welding (SMGW) processing is performed. Prior to this step, step 114~! At step 18, the download (DL) from the 2nd floor of the factory to the IF is executed.

That is, in step +14, the roof is lowered from 2F to IF, in steps 115 and 116, the left and right rear inner panels are lowered, and in steps 117 and 118, the left and right side panels are lowered, respectively. Note that in steps 119 and 120, the left and right sides of the pillar inner are lowered, respectively. Next, in step 121, additional welding is performed on the sub-main general welding, and similarly, in step 122, additional welding is performed using spot welding Rohot (SR). Then,
In step 123, final MIG welding is performed, and if necessary, in step 124, a spot welding supplementary step (complementary step by dispatching people in case of robot trouble) is executed, and in step 125, doors and the like are attached. Additionally, in steps 126 to 132, the hood is assembled, the trunk is assembled, the left and right front doors, the left and right rear doors are assembled, and the left and right fenders are assembled.
These steps are performed in parallel with or in advance of the previous steps.

FIG. 5 shows the state of each line in the production main 5. Lines 203 to 212 are provided around the management office 201 and the maintenance department 202 for each welding process. In the diagram, the black areas are areas where welding is performed automatically, the hatched areas are areas where welding or manual welding is performed, and the white areas are areas where vehicle model change setup is being performed. .

Considering the effects of this embodiment, it is as follows.

(1) Processing data for the body 6 and conversion files for aggregation are collectively managed by the host computer 1, which is a higher-level controller, and after being distributed to the line area computers 2A and 2B, the processing information is aggregated. Therefore, unlike the conventional method where operators aggregate processing instruction data each time, it is possible to reduce the number of man-hours required for inputting or changing processing orders and conversion files, increasing the efficiency of production management. It's coming. That is,
The efficiency of data management is greatly improved by aggregating processing information, and even if there is a change in the processing order or conversion file, it is possible to respond immediately, and it is possible to realize the construction of an efficient automated line system. can.

That is, processing of machining data is improved by aggregating the number of machining machines and collectively setting aggregation codes in deriving machining ranking data for each line. For example, from a parts list, create a list of partial configurations (derivative specifications list), model patterns, use of derived patterns - create a list, use M/C operation patterns - create a list, etc. to perform detailed aggregation of derivatives. By doing
It is possible to improve the data usefulness (-originality) by combining the machining order data and the M/C operation pattern, and to improve the data usefulness (-originality) by combining the machining order data and the workpiece material.

In addition, even if there is a change in machining order, parts list, M/C operation pattern, etc., the management before and after the change, management of switching timing, and data storage can be performed all at once on the host computer. 1, the input of change data is easy and the burden on the operator is reduced.

(II) In addition, in this embodiment, network 3.3A is used to distribute processed information and also to store and transmit files, which improves the reliability of data receiving equipment, prevents loss of received data, and prevents duplication. This can be prevented. In particular, data settings, storage, and processing are performed by storing setting data from a derivative aggregation maintenance computer on a file server, and sending setting data from the file server to the line area computer and from the line area computer to the controller. Since the functions are independent, it is possible to improve operability and data reliability. In addition, it is flexible in changing the processing order and converting converted files, always retains only the latest data, ensures data reliability, and has excellent data maintainability. It should be noted that if the number of communication lines in the network 3 is set to an appropriate number, the effect that the load on the network 3 can be reduced can also be obtained.

(■) In data processing, data recognition by the operator is improved by counting the number of machines (processing processing order data) by comparing the processing aggregate data with the aggregate code file. Furthermore, by performing data processing in a middle-level controller, it is possible for a higher-level controller to monitor the data processing status of the middle-level controller.

In the above embodiment, welding is performed as the processing for the workpiece, but the application of the present invention is not limited to this, and can also be applied to other processing, such as assembly. Moreover, the workpiece is not limited to the body of a vehicle, but may be other objects.

Furthermore, in the embodiments described above, processing information for each line is collected by a middle-level controller, but the present invention is not limited to this, and may be performed by, for example, a higher-level controller.

"Effect" According to the present invention, machining order data for workpieces and conversion files for aggregation are collectively managed by a higher-level controller, and a middle-level controller receives the machining order data distributed from an upper-level controller. Since processing information is aggregated for each line using data and the conversion file, it is possible to reduce operator man-hours, and
By aggregating processing information, data management efficiency can be improved, and the occurrence of human error can be significantly reduced. As a result, it is possible to construct an efficient automated line system, and the efficiency of production management can be improved. Furthermore, since files are stored and transmitted, it is possible to improve the reliability of the data receiving equipment and prevent data from being lost or duplicated.

[Brief explanation of drawings]

Fig. 1 is a basic outline of the present invention, Figs. 2 to 5 are diagrams showing an embodiment of the production management system according to the present invention, and Fig. 2 is a schematic diagram showing a network in the welding department of the automobile production line. 3 is a diagram showing the outline of the computer network of the processing instruction system, FIG. 4 is a diagram showing the specific process of the welding process, and FIG. 5 is a diagram showing the state of each production line. FIG. 6 is a diagram explaining the processing order of the conventional production management system. 1... Host computer (upper level controller), 2C, 2D, 2E... Derived aggregate maintenance computer (middle level controller), 2A, 2B... Line area computer (lower level controller), 3 ... Network, 3A... Computer network, '4 A~4
X...Sequencer (processing execution means), 5...
・Production line, 6...Body (workpiece), lO...Switcher, 11.21...Disk drive device, 12.22.
42... Printer, 13.23.43... Keychain, 14.24.4
4 - CRT display, 25 Trannova, 26... PC net, 31-35... Performance monitor computer 41...
Main body, 51... Line server, 52... Power supply device.

Claims (2)

[Claims] (1) A production line that transports workpieces, including different types, from the input section to the delivery section in a predetermined order and by a predetermined number of machines; For each model,
A high-level controller that sets and stores processing details for each model and distributes information on the processing details using a network, and divides the processing order information into model derivative classifications for each processing process on the production line. A middle-level controller that creates a conversion file and distributes the conversion file to a higher-level controller; and a middle-level controller that receives processing order information and the conversion file from the upper-level controller, and processes the processing order information based on the conversion file. A lower-level controller that converts and aggregates processing instruction information for each process and provides processing instructions corresponding to the processing content of the workpiece for each line, and a lower-level controller that is placed within the area of the production line and is based on processing instructions from the lower-level controller. processing execution means for executing a predetermined processing corresponding to each model derivation, etc., on each line in the order on a predetermined number of workpieces;
A production management system characterized by: (2) The lower controller stores the settings of model-specific derived aggregation codes for each line, and options for each line as a file for converting and aggregating processing information for each line distributed by the upper controller. Include at least one of the following: code settings, M/C operation pattern code settings for each line, workpiece material code settings for each line, and representative value settings for aggregate codes for each line. The production management system according to claim 1, characterized in that: