JPH05278816A - Picking work support system - Google Patents

Abstract

PURPOSE:To provide a picking work support system allowing a rapid and efficient picking work by a worker. CONSTITUTION:To an inventory management computer 8 for controllably managing and storing the inventory data in a part storing area 3 are connected a data input device 6 for inputting the information of a part 1 in a pallet 2a newly supplied to the part storing area 3; a carrying-in instructing device 7 for calculating the optimum storing position of the pallet 2a allowing an effective picking work and instructing it to a worker A; and an intended pallet instructing device 9 for calculating the storing position of an intended pallet 2c capable of most efficiently conducting the picking work and instructing it to a worker B, respectively.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a picking work support system, and more particularly to a picking work support system that enables efficient picking of parts for which delivery has been requested from stock.

[0002]

2. Description of the Related Art FIG. 9 is a schematic view showing an example of a conventional picking operation in an automobile manufacturing factory, and illustrates an automobile bumper as a part. The shape of an automobile bumper varies depending on the type of vehicle, specifications, and the like, and generally, the bumper of the same shape has a plurality of types of colors and patterns.
FIG. 9 shows bumpers 1 each having three types of shapes and colors (see (a) and (b) of the same figure). As shown in the drawing, these various types of bumpers 1 are loaded on a dedicated pallet 2 for each component shape capable of loading a plurality of bumpers of the same shape, and are stored in a component inventory area 3. The parts supply worker A carries in a pallet 2a full of bumpers 1 to the parts inventory area 3 while carrying out an empty pallet 2b in the parts inventory area 3 to the outside.
When a component delivery request from the bumper assembly process or the like is transmitted to the picking operator B via the component delivery instruction device 4,
The picking operator B finds the bumper 1 of the requested type from the dedicated pallet 2 in the parts inventory area 3, picks it up (this work is called picking), and loads it on the delivery pallet 5 or the like. Conventionally, the component picking work has been performed in this manner.

[0003]

However, in such a conventional system, the picking operator B cannot accurately grasp where and what is in the parts inventory area 3, and a delivery request is made. There is no choice but to go to the parts inventory area 3 each time to find a part that was found and pick the corresponding part found first. Therefore, picking work takes time and there is a possibility that parts with different specifications may be picked. In addition, parts are randomly picked from various pallets 2, so many pallets 2 with missing teeth are present. There is a problem that it is difficult to use the remaining parts inventory area 3 efficiently.

The present invention has been made in view of such conventional problems, and there is a delivery request by instructing the picking operator of the position of the target pallet with the highest work efficiency that satisfies the delivery request. It is an object of the present invention to provide a picking work support system that enables efficient picking of various parts from stock.

[0005]

SUMMARY OF THE INVENTION To achieve the above object, the present invention provides a dedicated pallet which is stored in an inventory area and is capable of loading a plurality of types of a plurality of types of parts, and which is supplied to the inventory area. And part information input means for inputting part information in the dedicated pallet, and inventory information storage means for storing arrangement information of the dedicated pallet stored in the inventory area and part information in each of these dedicated pallets. The optimum storage position of the dedicated pallet in the stock area that enables efficient picking work based on the input information from the parts information input means in the pallet and the stock information stored in the stock information storage means. The loading pallet storage position calculating means for calculating and the stock information storing means for storing the parts information to be picked are input. Picking component loading pallet storage position calculation means for calculating the storage position of the dedicated pallet for loading the picking components in the stock area that can most efficiently perform the picking work based on existing inventory information. ..

[0006]

According to the present invention having the above-described structure, when parts of each type are loaded on the exclusive pallet and supplied to the stock area, all the exclusive pallets supplied by the parts information input means in the pallet. The part information in is input,
Based on the input information and the inventory information stored in the inventory information storage means, the loading pallet storage position calculation means,
The optimum storage position of the dedicated pallet in the inventory area that enables efficient picking work is calculated. When the dedicated pallet is stored in the stock area according to the calculation result, the stock information storage means updates the stored contents to the latest one. After that, when the component information to be picked for which the delivery request is made is input, the picking component loading pallet storage position calculation means most efficiently performs the picking work based on the inventory information stored in the inventory information storage means. The storage position of the dedicated pallet for loading the picking parts in the stock area which can be achieved is calculated. Then, according to the calculation result, the desired component is efficiently picked from the dedicated pallet.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described in detail below with reference to the drawings. FIG. 1 is a schematic configuration diagram of a picking work support system according to an embodiment of the present invention. Here, similarly to the above-described conventional example, a bumper of an automobile will be described as an example as a component. The same parts as those in FIG. 9 are designated by the same reference numerals.

This system has a dedicated pallet 2 on which a plurality of different types of bumpers 1 having different vehicle types, specifications, colors, etc. can be loaded according to their shapes, and the various bumpers 1 supplied to the parts inventory area 3 are parts supplied. The operator A loads the dedicated pallets 2 and stores them in the parts inventory area 3. The external dimensions of these dedicated pallets 2 are all the same. In the work area of the parts supply worker A, the bumper 1 in the pallet 2a newly supplied in the parts inventory area 3 is supplied.
Data input device 6 consisting of a touch panel or the like for inputting various parts information such as vehicle type, specifications, color, number of loaded cars, etc., various data input by this data input device 6 and inventory stored in an inventory management computer described later. Based on the data, the pallet 2 to the parts inventory area 3 indicating which position in the parts inventory area 3 the pallet 2a should be stored in is the most efficient picking operation.
A loading instruction device 7 including a terminal device or the like for calculating the optimum storage position of a and instructing it to the component supply worker A is provided. The parts supply worker A operates the data input device 6 to input the bumper information in the carry-in pallet 2a, and stores the pallet 2a at a designated position in the parts inventory area 3 according to the instruction of the carry-in instructing device 7. become. In addition, a limit switch (not shown) for detecting whether or not the pallet 2 is seated is provided in each section in the parts inventory area 3.

Both the data input device 6 and the carry-in instructing device 7 indicate, based on the data from these devices, which position in the parts inventory area 3 the pallet 2 in which the bumper 1 of what kind and how many are currently loaded. It is connected to an inventory management computer 8 that manages and stores inventory data.
The inventory management computer 8 also performs various calculation functions as described later.

Further, in the work area b of the picking worker B who actually performs the picking work, the bumper 1 which has been requested to be delivered based on the inventory data stored in the inventory management computer 8 is currently in the parts inventory area 3. It is determined which pallet 2 is loaded, and when there are a plurality of pallets 2, the storage position of the target pallet 2c that can most efficiently perform the picking work is calculated and the picked worker B is given the calculated storage position. A target pallet instruction device 9 including a touch panel and the like for transmitting display is provided to the inventory management computer 8. Picking operator B
Picks the bumper 1 requested for delivery from the pallet 2c designated by the target pallet designating device 9,
It will be loaded on the delivery pallet 10 or the like.

The pallet internal component information input means is the data input device 6, the inventory information storage means is the inventory management computer 8, the carry-in pallet storage position calculation means is the carry-in instruction device 7, and the picking component loading pallet storage position calculation means. Are formed by the target pallet instruction device 9, respectively.

Next, an example of the operation of the present system thus constructed will be described with reference to the flow charts of FIGS. 2 to 5. FIG. 2 shows the initial setting of the system and the loading of the OK bumper into the parts stock area. Flowchart of Figure 3,
FIG. 4 is a flowchart for picking work, and FIG.
Is a flowchart showing the contents of the subroutine in FIG.

First, the initial setting of the system and the carry-in of the OK product bumper into the parts inventory area are performed according to the flow chart of FIG. That is, when operating this system for the first time, first, the layout diagram of the parts inventory area 3 and the inventory management of the vehicle type, specifications, colors, and number of loaded bumpers 1 in the pallet 2 stored in each section of the parts inventory area 3 are managed. Input to the computer 8 for initial setting (S1). This initial setup should only be done when the system is first run.

To actually operate the system, the schedule of the bumper 1 to be used is entered in advance in the memory of the inventory management computer 8 in the form of the planned gross number for each vehicle type, specification and color (S2). ). Then, the inventory management computer 8 calculates the use frequency coefficient of each bumper 1 based on this schedule (S3). This usage frequency coefficient is a ratio in the whole, and its calculation is performed in consideration of the current inventory quantity. FIG. 6 shows an example of the calculation result of the usage frequency coefficient.

OK carried from the bumper manufacturing process
The product bumper 1 is loaded on the dedicated pallet 2a by the component supply operator A by shape (S4). Then, the component supply operator A operates the data input device 6 such as a touch panel to input the component data such as the vehicle type, specification, color and number of the bumper 1 loaded on the pallet 2a (S5). These operations are repeated until the pallet 2a is full (S6).

The carry-in instruction device 7 calculates the usage frequency value of the bumper in the pallet based on the bumper information in the pallet from the data input device 6 and the usage frequency coefficient of each bumper 1 stored in the inventory management computer 8. (S7), it is determined whether the usage frequency value is large (S8). When the usage frequency value of the bumper in the pallet is large as a result of this determination, the carry-in instruction device 7 causes the carry-in instructing device 7 to select an empty space closer to the picking operator B from the empty spaces 3a (for example, the empty space (44) in FIG. ) Is graphically instructed to the component supply operator A on the screen (S9), while if the use frequency value of the bumper in the pallet is not large, the picker B is distant from the empty space (for example, the empty space in FIG. The section (28)) is graphically instructed to the component supply worker A on the screen (S10). In this way, the component supply worker A is instructed about the optimum storage position of the carry-in pallet 2a in the component inventory area 3 that enables efficient picking work. Then, the parts supply worker A is in the parts inventory area 3
The OK product loading pallet 2a is loaded and placed in the designated section in the inside (S11).

The pallet 2a is opened by the limit switch.
If it is confirmed that the seat is present (S12), the inventory management computer 8 automatically updates and stores the latest inventory layout diagram showing the inventory status of the bumper in the pallet in the parts inventory area 3 (S13).

Next, the actual picking work is performed according to the flowcharts of FIGS. 3 and 4. That is, first, when the delivery instruction information such as the assembly trim-in information is input to the target pallet instruction device 9 (S14), the target pallet instruction device 9 causes the vehicle type / specification / specification of the requested delivery of the bumper 1.
The color is recognized (S15), and further, based on the inventory data stored in the inventory management computer 8, firstly, the pallet 2 in which the bumper 1 requested to be delivered is loaded and the loading number is the smallest is selected. Search (S16). If such pallets 2 are present at multiple locations, the second
Further, among them, the pallet 2 closest to the picking worker B is searched (S17), and if there are still a plurality of pallets, thirdly, the pallet 2 having the largest use frequency value is searched among them. Yes (S18). Such S16
When the target pallet 2c that enables the most efficient picking work is selected through the steps of to S18, the target pallet instructing device 9 graphically indicates the storage position of the pallet 2c to the picking operator B on the screen (S).
19). Then, the picking operator B picks the desired bumper 1 from inside the pallet 2c at the designated position and transfers it to the delivery pallet 10 (S20).

With this picking operation, the inventory management computer 8 updates the inventory data on the pallet 2c by the amount of the bumper that has been picked and reduced by one (S21), and determines whether or not the pallet 2c has become empty. Is determined (S22). If the pallet 2c is empty as a result of this determination, the inventory management computer 8 instructs the picking operator B to pay out the pallet 2c via the target pallet instruction device 9 (S23), but if not empty, S26. Proceed to. When there is a pallet payout instruction in S23, the picking operator B carries out the pallet 2c payout work in accordance with the instruction (S24). When the presence detection limit switch is turned off by paying out the pallet 2c, the inventory management computer 8 causes the parts inventory area 3
Update the data related to the pallet 2 that is present inside (S
25).

With the update of the inventory data, the inventory management computer 8 calculates the usage frequency value of each pallet 2 in the parts inventory area 3 (S26) and the necessity of changing the pallet layout (S27). The processing contents of the subroutine of S27 will be described with reference to the flowchart of FIG. 4. In the inventory management computer 8, for example, as shown in FIG. 8, the pallet E becomes empty, and the picking operator B moves the empty pallet E from the section (46). When the pallet is paid out, the pallet with the highest frequency of use is searched from the remaining seated pallets 2 (S40). As a result, if three pallets F, G, and H are selected (S41),
Subsequently, the inventory management computer 8 calculates the time required for picking all the bumpers in each pallet F, G, H from the walking distance and walking speed of the picking operator B and the number of loaded bumpers 1. Then, the time required to transport the pallet to the empty section (46) for each pallet F, G, H is calculated from the walking distance and walking speed of the picking worker B (S42) (S43). Then, based on the two times calculated for each of the pallets F, G, and H in S42 and S43, which pallet should be transported to the section (46) to shorten the time is calculated, and the pallet layout is changed. Necessity is calculated (S44).

Then, returning to the main flow, the inventory management computer 8 calculates the result of S27 (for example, pallet G).
If the pallet layout needs to be changed based on the result that the time can be shortened most by moving the pallet to the section (46) (S28), if the pallet layout needs to be changed as a result of this determination. The picking operator B is graphically instructed to change the layout on the screen via the target pallet instruction device 9 (S29), and if there is no need to change the pallet layout, the process proceeds to S35.

The picking operator B who received the instruction to change the pallet layout in S29 decides whether or not to change the layout as instructed (S30). If the layout is not changed, "NO" is displayed on the touch panel or the like. A signal is input and the process proceeds to S34. However, if the layout is to be changed as instructed, a "yes" signal is input from the touch panel or the like (S31) and the layout of the palette G is changed (S32). The inventory management computer 8 detects the end of the layout changing work by turning on / off the presence detection limit switch (S33).

Next, the inventory management computer 8 executes S2
The necessity of swapping bumpers between pallets is calculated by the same calculation method as in 7 (S34), and it is determined whether bumpers need to be replaced between pallets based on the calculation result (S35). As a result of this determination, if it is not necessary to replace the bumper, the process returns to S14, but if replacement of the bumper is required, the picking operator B is graphically instructed to that effect on the screen via the touch panel (S36). Receiving this instruction, the picking operator B decides whether or not to replace the bumper as instructed (S37), and when not replacing the bumper, inputs a "NO" signal from the touch panel and returns to S14. If you want to change the bumpers between pallets as instructed, click "Yes" from the touch panel.
Is input (S38) and bumper replacement work between pallets is performed (S39). When the stock management computer 8 detects the end of this work, it returns to S14 and stands by.

As described above, according to the present embodiment, the stock state of the parts (bumpers) 1 is managed so that the picking work can be always performed efficiently based on the usage frequency value of each pallet 2 in the parts inventory area 3. On the other hand, when a delivery request for a component is made, the position of the pallet at which the target component can be picked is calculated most efficiently, and the picking operator B is specifically instructed where to place the component to be picked. As a result, not only is it possible to perform picking work in an extremely short time, but even unskilled workers do not pick parts with different specifications, and use the parts inventory area efficiently. Is now possible.

In this embodiment, the optimum storage position of the pallet 2a in the parts inventory area 3 is determined by the carry-in instruction device 7, and the position of the target pallet 2c on which the bumper to be picked is loaded is determined by the target pallet instruction device 9. Although they are individually calculated, it goes without saying that these calculations may be performed by the inventory management computer 8. In this case, the carry-in instructing device 7 and the target pallet instructing device 9 have a function of graphically displaying the calculation result of the inventory management computer 8 to the workers A and B.

[0026]

As described above, according to the present invention, it is possible to significantly reduce the time required for the picking work while preventing mistakes of the picking work by the worker, and to effectively use the parts inventory area. ..

[Brief description of drawings]

FIG. 1 is a schematic configuration diagram of a picking work support system according to an embodiment of the present invention.

FIG. 2 is a flowchart of initial setting of the system of FIG. 1 and loading of OK parts into a stock area.

3 is a part of a flowchart of a picking operation of the system of FIG.

FIG. 4 is a continuation of the flowchart of FIG.

5 is a flow chart showing the contents of a subroutine in FIG.

FIG. 6 is a diagram for explaining the flowchart of FIG.

FIG. 7 is a diagram for explaining the flowchart of FIG.

FIG. 8 is a diagram for explaining the flowchart of FIG.

FIG. 9 is a schematic view showing an example of a conventional picking operation.

[Explanation of symbols]

1 ... Bumper (parts) 2 ... Exclusive pallet 3 ... Parts inventory area 6 ... Data input device (parts information input means in pallet) 7 ... Carry-in instruction device (carry-in pallet storage position calculation means) 8 ... Inventory management computer (stock information storage 9) Purpose pallet instruction device (picking component loading pallet storage position calculation means)

Claims (1)

[Claims] 1. A dedicated pallet that is stored in a parts inventory area and is capable of loading a plurality of types of a plurality of types of parts, respectively, and a pallet for inputting parts information in the dedicated pallet supplied to the parts inventory area. Internal parts information input means, inventory information storage means for storing the layout information of the dedicated pallets stored in the parts inventory area and the parts information in each of these dedicated pallets, and input from the pallets internal parts information input means And a carry-in pallet storage position calculating means for calculating an optimum storage position of the dedicated pallet in the parts inventory area that enables efficient picking work, based on the information and the stock information stored in the stock information storage means. When the component information to be picked is input, based on the inventory information stored in the inventory information storage means, A picking component loading pallet storage position calculating means for calculating a storage position of the dedicated pallet for loading the picking components in the component inventory area capable of performing the most efficient picking work; ..