JPH06168249A - Mixed stream production system and operating method for the same - Google Patents

Abstract

PURPOSE:To diagnose the abnormality of a production line at an early stage by monitoring the operating condition of the production line and to output a work instruction to each worker. CONSTITUTION:Concerning the mixed stream production system and the operating method for the same composed of respective job sites for assembly and test on the single production line, plural line terminal equipments 3 installed at those job sites, communication storage unit 4 added to a product or a pallet to mount the product for making the streams of an object and information coincident and storing manufacture data for each product by communication with the line terminal equipments when conveying the pallet, line host control part 5, terminal equipment 6 for line host management and fault terminal equipment 7, and the line host control part 5 monitors parameters related with time management for the operating condition of the production line, quality conditions and states of workers, compares them with threshold values, displays the respective work instructions of attention, danger and line reconstitution and stops the production line when the fault is serious.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mixed-flow production system for producing a wide variety of products in one line and an operating method thereof, and more particularly to a mixed-flow production system for monitoring the operating condition of a production line and an operating method thereof.

[0002]

2. Description of the Related Art Generally, a product production line supplies parts required for assembling a product, assembles and manufactures the product, tests and inspects the performance of the product after the assembly is completed, and passes a product that has passed the test inspection to a packinghouse. It consists of a series of work steps until the flow. It is suitable for mass production if a production line is provided for each product, but in the case of high-mix low-volume production, the space and production equipment in the factory increase, and in the case of low-volume production, the idling of workers There is a problem that a lot of time is wasted in a space in a factory, production equipment, and workers, and in order to solve this problem, the applicant of the present invention previously applied,
In other words, in order to flexibly handle high-mix low-volume production and to produce multiple types of products, work instructions necessary for workers in each process of the production line and information regarding defects that occurred in each upstream process of the production line are automatically provided. In addition, we have developed a mixed-flow production system and its operation method that automatically provides a test report to the workplace immediately before sending it to the packing place.

In such a mixed-flow production system and its operation method, the time required for the workers at each work site of the production line to simultaneously start and finish a predetermined work process varies depending on the respective workers, and the same work is performed. Even for a person, the work efficiency changes depending on the working hours of the day. On the other hand, the mixed-flow production system and the operation method thereof are produced without knowing the occurrence status of the incomplete rate of the product due to the lack or defect of the assembled and tested product.

[0004]

However, in such a mixed-flow production system and its operating method, production is continued without knowing whether the production line is in a normal state or an abnormal state, and in the abnormal state, productivity is increased. There is a problem in that On the other hand, if the product is manufactured without knowing the occurrence rate of the unfinished product, there is a problem that a large amount of unfinished products are produced.

In view of the above-mentioned problems, the present invention monitors the operating conditions related to the occurrence of work efficiency and product incomplete rate of each worker in a production line, early diagnoses abnormalities in the production line, and responds accordingly. It is an object of the present invention to provide a mixed-flow production system that outputs a specified work instruction to each worker and an operating method thereof.

[0006]

FIG. 1 is a basic configuration diagram of a mixed flow production system of the present invention. The mixed flow production system of the present invention that achieves the above-mentioned object is an assembly site 1 for assembling parts delivered in an assembling order on a single production line to assemble a plurality of types of products one by one, and the performance of the products after the assembly is completed. And a plurality of line terminals 3 provided at each of the assembly station 1 and the test station 2, and a product or a pallet on which the product is placed in order to match the information flow. , A communication storage unit 4 that communicates and stores the manufacturing data of each product with the line terminal 3 when a pallet is conveyed to the production line, and a communication storage unit 4 in each of the assembly site 1 and the test site 2 The stored data of the above is read via the line terminal 3, and a work instruction sheet is issued to each worker of the assembly site 1 and the test site 2 based on the read data. For the line host control unit 5 that outputs to the terminal device 3, and for the line host management that directly inputs and outputs data related to master file maintenance, work instruction management, progress management, schedule editing, machine history management, etc. to the line host control unit 5. Terminal 6
Then, for the defective product to be replaced, enter the data of the failure content (error code), enter the data of the failed part determined to be the failure, and replace the failed part to repair the failure. In the mixed flow production system including the faulty terminal 7 that cancels the data of the faulty part and the operating method thereof, the line host control unit 5 controls the production line operation status on time management, quality status and worker status. The parameters related to the above are monitored, the data of the parameters are compared and discriminated with the threshold value of the caution level, and when it is higher than the threshold value of the caution level, the operator is alerted and compared with the threshold value of the danger level. If it is higher than the critical level threshold, a warning is displayed to the worker, and a work instruction to reorganize the line is displayed to compare with the critical failure level threshold. Important is higher than the failure level threshold stops the production line, displays the work instruction of what to do next to the operator. The respective displays are configured to be displayed and output via the line terminal 3 or the line host management terminal 6.

In the mixed production system of the present invention, the parameter relating to the time management is configured to obtain the data stored in the communication storage unit 4 by communicating with the line host control unit 5 via the line terminal 3. .

In the mixed production system of the present invention, the parameter relating to the quality condition is obtained from data communicated from the line terminal 3 or the faulty terminal 7 to the line host controller 5.

In the mixed-flow production system of the present invention, the parameter relating to the condition of the worker is obtained by signals detected by a plurality of sensors provided in the worker's workplace, and the signal of the sensor is input to the programmable controller. Further, it is configured to communicate with the line host controller 5 via the line terminal 3.

Further, in the operation method of the mixed flow production system, the line host control section (5) monitors the operating status of the production line, parameters relating to time management, quality status and worker status, The data is compared and discriminated with a caution level threshold consisting of one or more stages, and when the data is higher than the caution level threshold, a warning is issued to the operator, and the line terminal (3) or the line host management It is characterized in that it is displayed via the mobile terminal (6).

Further, in the operating method of the mixed flow production system, the line host control section (5) monitors the operating status of the production line, parameters relating to time management, quality status and worker status, The data is compared and discriminated with a threshold value of the risk level consisting of one or more stages, and when the data is higher than the threshold value of the danger level, a warning is given to the worker, and a work instruction for reorganizing the line,
It is characterized in that it is displayed through the line terminal (3) or the line host management terminal (6).

In the method for operating the mixed flow production system, the lines are reorganized by changing the man-hours of each worker, changing the number of workers, or changing the layout of workers according to the rating of the workers. And

In the method for operating the mixed flow production system, the line host control section (5) monitors operating conditions of the production line, parameters relating to time management, quality condition and operator's condition, and outputs data of the parameters. 1) Comparing and judging with the threshold value of the critical fault level consisting of one or more stages, and when it is higher than the threshold value of the critical fault level, the production line is stopped and a work instruction for the next work to be given to the operator It is characterized in that display output is performed via the machine (3) or the line host management terminal machine (6).

[0014]

In the mixed-flow production system and the method of operating the same according to the present invention, the line host control section 5 reads the data written in the communication storage unit 4 conveyed to the assembly station 1 and the test station 2 via the line terminal 3. Based on the read data, each of the workers at the assembly site 1 and the test site 2 is caused to output a work instruction through the line terminal device 3 by the display device of the line terminal device 3, and further by the information from each line terminal device 3. The line host control unit 5 monitors the operational status of the production line for time management, monitors the abnormal status of parameters related to the quality status and the operator's status, compares the data of the parameters with a caution level threshold value, and determines the caution level. When it is higher than the threshold value of
Furthermore, it is compared with the threshold of the danger level, and when it is higher than the threshold of the danger level, a warning is displayed to the worker,
The display of the work order to reorganize the line is further compared with the critical failure level threshold, and when it is higher than the critical failure level threshold, the production line is stopped and the worker is informed of the next work to be performed. The display of the work instruction is displayed and output to each work site via the line terminal 3 or the line host management terminal 6, respectively.

[0015]

FIG. 2 is a diagram showing an embodiment of the mixed flow production system of the present invention. In the figure, M1 to M6 are assembly sites for assembling products, and T1 to T14 are test sites for testing and inspecting the equipment after assembly is completed. Here, the equipment is the first test site T where all the components that make up the product are assembled.
It means an assembly of parts until the assembly is completed before being transported to 1. The assembling machines 1 to 6 are assembled at the assembling sites M1 to M6, respectively. In the assembling sites M1 to M6, necessary parts are stored in a temporary parts supply station (not shown) according to the type of product, and are delivered to the assembling sites M1 to M6 by a transport vehicle in the assembling order. There are some assembly sites that are not used depending on the number of parts. For example, assembly stations M1 to M
When the assembly is completed up to 4, the assembling sites M5 and M6 are not used. In this embodiment, a communication storage unit, that is, an ID card (not shown) that is a data carrier is mounted on a pallet on which the product is placed, and the ID card is used to provide information necessary for producing the product through the line terminal. It is transmitting and receiving with the host controller.

FIG. 3 is a diagram showing the hardware between the ID card and the line host controller. In the figure, reference numeral 11 refers to an optical ID unit, which is an ID card in the present invention. The ID card 11 is attached to a product or a pallet on which the product is placed, while an optical terminal 12 is installed at each assembly site and each test site.
When the pallet is conveyed, it is detected by the photoelectric switch etc. provided at each assembly site or each test site, and the sequencer 1
The conveyor (not shown) is stopped by 4 and each work of assembly or test is started, but before that, the ID card 11 and the optical terminal 12 communicate with each other to read / write data. The line host control unit 1 reads and writes these data.
The transmission / reception signal of the optical terminal 12 is amplified by the control unit 13 under the control of 6 through the line terminal 15 of each part, and the control unit 13 is directly connected to the line terminal 15 and the R via the sequencer 14.
It is connected by the interface of S-232C.

Referring back to FIG. 2, an embodiment of the mixed flow production system of the present invention will be described in detail. The machine-in-process terminal, which is a line terminal at the assembly site M1, transmits a product code corresponding to the model to the line host control unit by keyboard input or bar code reading, and the line host control unit stores the product product stored therein. Code, management NO. And the process NO. , Work start time, work end time, test pattern, and other data for an ID card, which will be described later, are written to the ID card through the device in-process terminal, and the C provided in the device in-process terminal is written.
Output the assembly work instruction to the RT monitor or printer to notify the operator. The worker at the assembly site M1 starts driving the conveying means, that is, a conveyor (not shown) for sending the assembled product to M2 according to the work instruction.

At the assembling stations M2 to M6, the equipment terminals, which are the respective line terminals, operate from the ID cards of the pallets sequentially conveyed to the respective workplaces to the product code and management N.
O. Etc., and also reads the model, machine number, version number, and manufacturing date of each component of the equipment from the bar code attached to each component, for example, and sends those data to the line host control unit, and the line host The control unit outputs the assembly work instruction sheet corresponding to each of the assembly sites M2 to M6 stored in itself to the CRT monitor or printer provided in each equipment terminal to notify the operator. In this way, the worker starts driving the conveying means, that is, a conveyor (not shown) for sequentially sending the mounting machines 1 to 6 to the next assembly site, and finally transports the mounting machine 6 to the test site T1.

The entrance examination terminal, which is a line terminal at the test site T1, has the product code, the management code No., from the ID card of the conveyed pallet. And the individual model, number, version number, and manufacturing date of each component of the product are transmitted to the line host control unit by, for example, scanning the barcode attached to each component, and the line host control unit is After confirming whether or not there is a mounting failure in 6, the work instruction is output to a CRT monitor or printer provided in the entrance examination terminal to inform the operator, for example, that there is a mounting failure. Further, the entrance examination terminal uses the ID card for the process NO. ,
The work start time, work end time, and judgment result data indicating the presence or absence of a failure are written. Next, the worker mounts the equipment 6 on the test site T.
The driving of the conveying means for sending to 2, ie the conveyor (not shown) is started.

The line terminal at the test site T2 displays the product code, management N
O. Is sent to the line host control unit, and the line host control unit checks the soft keep, that is, whether or not to write the test program in the hard disk of the product, and outputs it to the CRT monitor or printer provided in the line terminal for work. If there is no soft keep, the worker immediately starts transporting to the next test station T3, and if there is a soft keep, temporarily pools it on the soft keep shelf and writes the test program on the hard disk of the product and then the next stage. Transport to the test site T3 of No.

The line terminal at the test site T3 displays the product code, management N
O. To the line host control unit, and the line host control unit checks whether or not the equipment 6 should be retired (returned to the repair process as a returned product), and a CRT monitor or printer provided in the line terminal. To inform the operator, if the operator confirms that he / she will retire, put the equipment 6 in the retirement area, and if he / she does not recognize that he / she wants to retire, confirm the setting instruction of the setting conditions of the high temperature aging / low temperature aging device. However, according to the setting instruction, the aging device is set, for example, the aging time with respect to the set voltage during aging such as the voltage VL (slightly less than 5V) for 2 hours, the voltage VH (more than 5V) for 12 hours, and the size of the equipment, in particular. The number of occupied stages of the aging device is set according to the height, and the conveyance means in the high temperature aging is started to drive toward the next test site T4.

The occupied number of stages is 6 for both the high temperature aging device and the subsequent room temperature aging device.
A conveying device for stages is provided, and one unit occupies two or three stages depending on the height of the unit. Further, the high temperature aging device is provided with a transport device on the outward path and the return route, and the room temperature aging device is provided with a transport device on the outward path only. Here, in addition to the test site T3, the retirement sites are test sites T4, T5, T
7 and T14 are similarly provided.

Test site T exiting the high temperature aging device
The line terminal in No. 4 is the ID of the pallet that was transported.
Product code from card, management No. Is sent to the line host control unit, and the line host control unit outputs it to a CRT monitor or a printer provided in the line terminal to inform whether or not the equipment 6 has an automatic voltage change. When it is confirmed that the automatic voltage adjustment is possible, the voltage setting is changed manually when it is confirmed that the automatic voltage adjustment is not performed, and the return path of the high temperature aging device is directed to the next test site T5, and the conveyance in the high temperature aging is performed. Start driving the means.

Next, the line terminal at the test site T5, which has left the return path of the high temperature aging device, displays the product code from the ID card of the conveyed pallet, the management number. To the CRT monitor or printer provided in the line terminal, and outputs the aging time for the aging device at room temperature, that is, the room temperature, and the number of occupied stages as described above. Notifying the person, the worker sets the aging time and the number of occupied stages of the room temperature aging device, and starts driving the conveying means in the room temperature aging device.

After the room temperature aging is completed, the line terminal at the test site T10 is transferred from the ID card of the carried pallet to the product code and management N when the product is transferred to the test site T10.
O. To the CRT monitor or printer provided in the line terminal, and the operator is informed whether the product is soft-keeping, that is, whether basic software (OS) is written. Inform the operator that after the writing process is executed when the soft keep is present, and when the soft keep is not present, the worker starts driving the transporting means to the packing place so as to start transporting to the test site T14 as it is.

Next, the line terminal at the test site T14 displays the product code, the management No. Is transmitted to the line host control unit, and the line host control unit causes the printer of the line terminal at the test site T14 to issue the test report. Also, the trial stocking process, that is, the line host control unit transmits a notification of the assembly inspection completion report to the production management system. In addition, the line host control unit communicates with the packing place host control unit in the packing place via LAN, and prepares the corrugated board required for packing by the printer or CRT monitor of the management terminal machine of the packing place host control unit. Notify the operator of the packing work instructions to. On the other hand, the line terminal of the test site T14 uses the ID card for the process number of the test site T14. , The work start time, the work end time, and the determination result data indicating the presence or absence of a failure are written. Finally, the worker starts driving a conveying means or conveyor (not shown) for sending the product to the packing place.

Further, a failure terminal is provided near the failure repair work site, and the failure content data for the failed product to be replaced is input through the failure terminal, and the failure part determined to be the failure is input. Data is input, and when the fault is repaired by replacing the faulty part, the data of the faulty part is canceled and input is performed to perform quality control.
The line host management terminal (not shown) stores data related to master file maintenance, work instruction management, progress management, schedule editing, machine history management, etc. on the same floor as the production line (not shown). ) Is used for direct input / output to / from. Further, the line host control unit outputs a work instruction document that minimizes takt time through each line terminal.

FIG. 4 is a diagram showing the format of the ID card. The ID card used in the embodiment has a storage capacity of 2 Kbytes, and as shown in the figure, 32 addresses (here, 1 byte 4 bits) of memory are allocated to each of 22 addresses, and its memory map is fixed at address 1. Product product code, management No. , Presence / absence of fault, line-out flag, line-in, VH / VL selection, line-out process, pallet return, re-input flag, NO. 1 keep flag, NO. 2 keep flag, VN, VL, VH automatic power variable, address 2 stores data related to line control such as high temperature VH aging time, high temperature VL aging time, normal temperature aging time, number of stages switching, and spare. Each process from address 3 to 8 from equipment 1 (assembly site M1) to equipment 6 (assembly site M6), and from addresses 9 to 20 from entrance examination (test area T1) to trial (test area T14) NO. , Start time, determination result, end time, and spare data are stored.

Here, the contents of the memory will be supplementarily described below. The fixed value indicates the head address of the memory and is set to 0. The product code of the product, the management number. Indicates the product model and machine, respectively, the presence or absence of a fault means the absence of a part or the presence of an abnormal test result, and the line-out flag indicates whether the product is assembled or tested until the first retirement after the fault is detected. The line-in is data for identification in order to prevent it from happening, and the line-in means data for re-injection, and indicates the presence / absence of retirement and at which step the retirement instruction was issued. For example, 00 indicates that there is no retirement, and 01 indicates that there is a retirement instruction in step 1. The VH / VL selection is for indicating whether VH or VL is set in the automatic power supply variable device provided in the test site T4, the lineout process indicates the retired process, and the pallet return indicates the pallet first. When returning to the process, it is data indicating which course of high temperature aging equipment is passed or bypassed, and the re-input flag indicates whether or not the product is a re-input product,
NO. The 1-keep flag indicates whether or not to load the test program. The 2 keep flag indicates whether to load the OS (basic program) on the hard disk,
VN, VL, VH automatic power source variable indicates whether or not the product has a function of automatically voltage varying.

The high temperature VH aging time, the high temperature VL aging time, and the normal temperature aging time at the address 2 are indicated as, for example, data 1230, which means that aging is set for 12 hours and 30 minutes.
It means setting to 2 or 3 steps. Address 3
No. 22 to process No. Indicates data indicating the assembling sites M1 to M6 or the test sites T1 to T14, the start time and the end time are written as days, hours, minutes, and seconds, respectively, and the determination result indicates the presence or absence of a failure result.

In this way, the data for each product is stored in the ID card, and is read and written at each assembly site and test site as the equipment is transported along the production line. Based on these data, up-to-date ( The latest) and accurate work instructions can be given, shared data can be held by communication with the quality information system and the production control system, and it is possible to support quality control and production control.

Prior to the explanation of FIG. 5, parameters used for the monitor in the mixed flow production system of the present invention will be explained. As parameters (A) time management,
There are parameters for three factors: (B) quality status and (C) worker status. (A) With regard to time management, there are tact time, line balance, and man-hour parameters (parameters) that are input from the line terminal. These parameters are based on the input data of the ID card, and the tact time at each process. The line balance is calculated as a time interval during which the product passes, the line balance is obtained by the difference between the maximum value and the minimum value of the tact time, and the work man-hour is obtained by subtracting the work end time from the work start time.
In addition, there are parameters and stagnation that are obtained as retention time in processes other than work by input from sensors.

(B) As parameters relating to the quality status, the frequency of occurrence in the same model, which is mainly collected from the faulty terminal when a fault occurs, the frequency of occurrence of each process, the frequency of occurrence of each content, the frequency of occurrence of each part, There are parameters for the occurrence of major failures.

(C) The parameters relating to the state of the worker include, as behaviors of the worker, a stop time at the same point, a stay time outside the normal range, and a movement frequency to the outside of the normal range. A sensor signal detected by a sensor provided in the line controller is input to the programmable controller and further communicated to the line host controller via the line terminal.

Next, the threshold table will be briefly described. In the embodiment, as a threshold value, a threshold value for calling attention level and a threshold value for calling danger level are provided.
This threshold value may be provided in a plurality of levels as required.

Next, the calculation of each parameter will be described in detail. Each parameter is defined as follows. (A) Time management: T _start : from the arrival time of the process to the work start time T _s0 : the arrival time of the process (nth unit) T _s1 : the arrival time of the process (n + 1st unit) T _end : the work end time of the process T _out: the delivery time from the process T _tact: process tact time _{(T tact = T s1 -T s0} ) T stop: stagnation _{(T stop = T out -T end} ) T kosu: man-hours _(T kosu = T _star - T _end ) T _bar : Line balance (T _bar = MAX (T _tact ).
-MIN (T _tact )) Here, T _start , T _s0 , T _s1 , T _end , and T _out are obtained from the input information read from the ID card,
T _tact , T _stop , T _kosu , and T _bar are obtained by calculation based on the input information read from the ID card.

(B) Quality situation: N_in-l : Number of line inputs (number of inputs in the first process) N_in-k : Number of passing processes (number of inputs in each process) N_err-d: Number of failures in the same model N_err-k: Number of failures in the same process N_err-n: Number of failures with the same content N_err-b: Number of failure occurrences in the same part Q_kisyu: Occurrence frequency of the same model (Q_kisyu= (N_err-d
/ N_in-l) × 100) Q_kotei: Occurrence frequency of the same process (Q_kotei= (N_err-k
/ N_in-k) × 100) Q_kisyu: Occurrence frequency of the same contents (Q_kisyu= (N_err-n
/ N_in-l) × 100) Q_kotei: Occurrence frequency of the same parts (Q_kotei= (N_err-b
/ N_in-l) × 100) where N_in-l , N_in-k , N_err-d, N_err-k, N
_err-n, N_err-bIs an obstacle terminal, line terminal or I
Obtained from the data entered from the D card,
Q _kisyu, Q_kotei, Q_kisyu, Q_koteiIs the demand
Calculated based on the collected data.

(C) Condition of worker: T _m-STP : Stop time at the same point T _m-out : Stay time outside the normal range (hours) C _m-out : Frequency of movement outside the normal range ( Number of times) Here, T _m-STP , T _m-out , and C _m-out are obtained by sensor signal input in the workplace of each worker.

Parameter data reading will be described below. (A) The work start time is I as time data of each work process.
The work end time is input from the D card by a keyboard input by the operator. Arrival and delivery times of products passing through each process are automatically collected as input information from an ID card attached to the products. The work end time is collected by allowing the worker to input it by a specific keyboard key or detecting the end of the automatic processing. (B) As fault information, data of various information such as model, generation time, generation process, fault content, and fault parts are input from the fault terminal, line terminal or ID card. When a failure occurs, the failure content (ID card, test result information by the test program written on the hard disk, etc.) is notified to the line host control unit. (C) As the position information of the worker, the cumulative time that the worker has existed in the longest area in the workplace, the staying time outside the normally existing range in the workplace, and the outside of the normally existing range in the workplace The data regarding the movement frequency is obtained from the input signal to the programmable controller of the sensor provided in the workplace and is stored in the storage unit of the line host control unit. For this sensor, a touch sensor or the like on the mat is laid at a position where the worker exists in each work place, and the movement of the worker can be monitored.

FIG. 5 is a flow chart of the monitor processing by the mixed flow production system of the present invention. The numbers following S in the figure indicate step numbers. (Step S1): The data in the memory of the line host control unit, FLG, are set to "normal" and initialized. (Step S2): The reading of the above-mentioned parameter data is executed. (Step S3): The above parameters are calculated. (Step S4): An important fault that should be particularly noted as a fault is registered in advance in a file relating to the fault by keyboard input of the fault terminal, and when the fault occurs, the contents of the fault are collated with the contents of the file relating to the fault, and the contents are When it is determined that there is a fault, the process proceeds to step S11 when it is determined that there is a fault, and to step S5 when it is determined that there is no fault.

(Step S5): Compare the data of each parameter with the threshold value of the corresponding caution level, and if the data of the parameter is lower or equal, step S5.
Returning to step 2, when it is high, the process proceeds to step S6. (Step S6): It is determined whether FLG is "normal" or not, and YE
If S, the process proceeds to step S13, and if NO, the process proceeds to step S7. (Step S7): The parameter data is compared with the corresponding threshold of the danger level. If the parameter data is lower or equal, the process returns to step S2, and if the parameter data is higher, the process proceeds to step S8.

(Step S8): FLG is set to "danger". (Step S9): Data of a corrected version (described later), which is a table obtained by calculating the optimum balance of the production line, is input to the production line. (Step S10): Output information to each line terminal regarding the work change instruction that instructs the work to be changed, which is judged from the corrected version.

(Step S11): The production line is stopped. That is, the new feeding to the production line is stopped, and the conveyors for transportation other than aging are stopped. (Step S12): Give a work instruction for the next work.
For example, (a) Retire the equipment that should not continue production due to a failure or the like in the middle of the production line (return to the repair process as returned goods). (B) Press the keyboard to notify the end. (C) Give an instruction to restart. (Step S13): I of the worker based on the input information
D (identification) NO. Change the data in the worker table showing the name, name, and rating. This change is based on the information from the ID card or the keyboard operation by the operator at the end of the work in each process, M1, M2, M3,
Calculate the work time of…, and obtain the rating of each worker as follows.

Scheduled work time = Standard work time × 100 / Rating data of worker table Actual work time = Standard work time × 100 / Current rating data of worker Here, the current rating data of the worker is an ID card or It is data obtained from the working time of each process obtained from the input data by operating the keyboard of the line terminal. From the above two equations, the current rating is obtained by the following equation. Current rating data of workers = (scheduled work hours /
(Actual man-hours) × rating data in worker table Further, in step S13, preparation of corrected work distribution,
That is, as described in detail in the specification of the present invention and the application filed at the same time, the start date of work, model code, device name, production number, work (work-in-progress) sequence and predetermined M ₁ Process up to the creation of a schedule (work in process) file related to the work start time of the work process and a work file for each process that indicates how many devices, what day, what time, and what work is to be executed for each process To execute. (Step S14): FLG is set to "Caution".

FIG. 6 is a diagram showing an optimum production line balance calculation procedure before correction, and FIG. 7 is a diagram showing an optimum production line balance calculation procedure after correction. In the figure, X _{1 to} X ₂₁ indicate the respective work man-hours, and A ₁ to
A ₃ dishes represents the number of steps of each step, showing a rating of R ₁ to R ₃ HA respective workers. Further, the figure shows an example in which the number of steps m = 3 and the number of operations n = 21. Each is calculated so as to minimize the line balance loss. A detailed description of this calculation is omitted because it has been described in detail in the specification of the present invention simultaneously filed with the present invention. FIG. 7 is a diagram showing an optimum production line balance calculation procedure when only the worker in the process M ₂ is changed from 80 to 70 in the rating of FIG.

[0046]

As described above, according to the mixed flow production system and the operating method thereof of the present invention, the operation status of the production line is monitored, the abnormality of the production line is early diagnosed, and the work instruction of the next work to be performed accordingly. It is possible to provide a mixed-flow production system that outputs to each worker and an operating method thereof.

[Brief description of drawings]

FIG. 1 is a basic configuration diagram of a mixed production system of the present invention.

FIG. 2 is a diagram showing an embodiment of a mixed production system of the present invention.

FIG. 3 is a diagram showing hardware between an ID card and a line host control unit.

FIG. 4 is a diagram showing a format of an ID card.

FIG. 5 is a flowchart of a monitor process by the mixed flow production system of the present invention.

FIG. 6 is a diagram showing a calculation procedure of an optimum production line balance before correction.

FIG. 7 is a diagram showing a procedure for calculating an optimum production line balance after correction.

[Explanation of symbols]

 1 ... Assembly place 2 ... Test place 3 ... Line terminal 4 ... Communication storage unit 5 ... Line host controller 6 ... Host management terminal 7 ... Failure terminal

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yasuaki Ishiyama No. 98, Unoke-nu, Unoki-cho, Hebei-gun, Ishikawa Prefecture 2 PIE Co., Ltd. (72) Kazuyuki Kajiwara 98 Uno-nu, Unoki-cho, Kawakita-gun, Ishikawa Prefecture Address No. 2 PF Corporation

Claims (11)

[Claims] 1. An assembly site (1) for assembling parts delivered in an assembly order on a single production line to assemble a plurality of types of products one by one, and a test and inspection of the performance and quality of the products after the assembly is completed. A test station (2), a plurality of line terminals (3) provided at least one in each of the assembly station (1) and the test station (2), and a product or a product are mounted to match the flow of information with an object. A communication storage unit (4) that is added to the pallet and communicates with the line terminal (3) to store the manufacturing data of each product when the pallet is conveyed to the production line; The storage data of the communication storage unit (4) is read via the line terminal (3) at each work site of the test site (2), and the assembly site (1) and the front are read based on the read data. A line host control unit (5) for outputting work instructions for each worker of the test station (2) to the line terminal (3), master file maintenance, work instruction management, progress management, schedule editing, machine history A line host management terminal (6) for directly inputting / outputting data relating to management and the like to the line host control unit (5) and a failure content data for a defective product to be replaced, A faulty terminal (7) for inputting data of a faulty part determined to be a fault and for canceling the data of the faulty part when the faulty part is replaced and the fault is repaired.
And a mixed-flow production system. 2. In the mixed flow production system, the line host control section (5) monitors operating conditions of a production line, parameters relating to time management, quality condition and worker's condition, and the parameter data is 1
The line terminal (3) or the line host management terminal ( 6. The mixed flow production system according to claim 1, wherein the mixed flow production system is displayed via 6). 3. In the mixed flow production system, the line host control unit (5) monitors operating conditions of a production line for time management, quality conditions, and parameters relating to a worker's condition, and the data of the parameters is 1
The line terminal (3) is used to make a judgment by comparing with the threshold of the danger level consisting of the above steps, and to alert the worker when the threshold is higher than the threshold of the danger level and to give a work instruction to reorganize the line. Alternatively, it is displayed through the line host management terminal (6).
Mixed production system described in. 4. In the mixed flow production system, the line host control unit (5) monitors operating conditions of a production line for parameters relating to time management, quality condition and operator's condition, and the parameter data is 1
By comparing with the threshold value of the critical fault level consisting of the above steps, when it is higher than the threshold value of the critical fault level, the production line is stopped and the operator is instructed to perform the work to be performed next by the line terminal ( 3. The mixed flow production system according to claim 1, wherein the output is displayed via a terminal 3) or a line host management terminal (6). 5. The time management parameter is obtained by communicating data stored in a communication storage unit (4) to a line host control unit (5) through the line terminal (3). The mixed flow production system according to claim 1. 6. The parameter relating to the quality condition is obtained from data communicated from the line terminal (3) or the faulty terminal (7) to a line host controller (5). The mixed flow production system according to 1. 7. The parameter relating to the condition of the worker is obtained from signals detected by a plurality of sensors provided in the workplace of the worker, the signals of the sensors are input to a programmable controller, and the line is further input. The mixed flow production system according to claim 1, wherein the mixed production system is communicated to the line host control unit (5) via a terminal (3). 8. In the mixed flow production system, the line host control unit (5) monitors operating conditions of a production line for parameters relating to time management, quality condition and operator's condition, and the parameter data is 1
The line terminal (3) or the line host management terminal ( 6) A method for operating a mixed-flow production system, characterized in that it is displayed via. 9. In the mixed flow production system, the line host control section (5) monitors operating conditions of a production line for parameters relating to time management, quality condition and operator's condition, and data of the parameters is 1
The line terminal (3) is used to make a judgment by comparing with the threshold of the danger level consisting of the above steps, and to alert the worker when the threshold is higher than the threshold of the danger level and to give a work instruction to reorganize the line. Alternatively, the method for operating a mixed flow production system is characterized in that the line host management terminal (6) is used for display. 10. The mixed flow production system, wherein the lines are reorganized by changing the number of man-hours of each worker, changing the number of workers, or changing the arrangement of workers according to the rating of the workers. The method for operating the mixed flow production system according to claim 9. 11. In the mixed flow production system, the line host control unit (5) monitors operating conditions of a production line, parameters relating to time management, quality condition and operator's condition, and data of the parameters is 1
By comparing with the threshold value of the critical fault level consisting of the above steps, when it is higher than the threshold value of the critical fault level, the production line is stopped and the operator is instructed to perform the work to be performed next by the line terminal ( 3) or a method for operating a mixed flow production system, characterized in that a display is output via a terminal (6) for managing a line host.