JPH06227629A - Sheet roll machining facility - Google Patents

Abstract

PURPOSE:To provide sheet roll machining facility which can obtain various kinds of split sheet roll at good timing and with a high yield. CONSTITUTION:Sheet roll machining facility is provided with a computer for production plan 1, an original roll storage device 2 which can take out a required original roll 7 based on the command of the computer for production plan 1, and a slitter-rewinder 3 which machines the original roll 7 which is taken out from the original roll storage device 2 into required split sheet rolls 4. Consequently, it is unnecessary to keep the stock of the split sheet roll in large quantitites for which it is difficult to know an order securely as in the conventional way. Also, it is possible to improve productivity for charged materials and energy greatly and shorten lead time. Further, it is possible to reduce the number of workers greatly.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet roll processing facility for dividing a strip-shaped sheet such as a plastic film into a plurality of strips and winding the sheet into a divided sheet roll.

[0002]

2. Description of the Related Art A divided sheet roll, which is the final product in a sheet roll processing facility, is a slitter rewinder, which is a raw roll which is an intermediate product by winding a belt-shaped sheet continuously formed by a film forming machine and not sent out by a winder. Thus, the strip-shaped sheet is rewound from the original roll, cut into a required width and wound up by a required length.

First, in a film forming machine, a raw material resin is melted by heat, and the melted raw material resin is continuously formed into a strip-shaped sheet by a flat or ring-shaped die whose gap is finely adjusted. Therefore, it is necessary to change the raw material, switching the type of band-shaped sheet to be molded, die gap or temperature, or switching the thickness of the band-shaped sheet that requires fine adjustment of the operating speed is an unavoidable adjustment loss, It is a factor that reduces productivity such as yield and operating rate in film forming machines.
That is, in this step, the production yield can be improved by continuously operating the film forming machine so that the largest possible lot can be produced without changing the product type or the thickness. For example, according to a one-year survey on the BOPP film forming process, the average of 10 lots produced by a mill roll with a diameter of about 800 mm was found. It causes a loss of 10 percent. By making this a double production lot, the loss ratio of each is 10% and 5
It can be halved to a percent loss.

Further, the divided sheet rolls produced by the slitter rewinder are required to satisfy various conditions according to the user's order, and the types thereof are enormous. For example, according to an example of a BOPP film manufacturer, there are five types of sheets, ten types of thickness, and a sheet width of 300 mm to 200 mm.
We have commercialized products up to 0 mm in units of 5 mm to reach about 300 types, and further have 10 types of winding length, 2 types of winding core diameter, 3 inches and 6 inches, and a packaging form for shipping. There are 4 types, and this is the reality of the market. All of these conditions are combined to form a product specification, and the product specification of the divided sheet roll that is the final product is about 1.2 million kinds (5 × 10 × 300 × 10 × 2 ×).
4).

In the conventional sheet processing equipment, although there is a means for storing the raw roll between the mill roll winder and the slitter rewinder, the capacity of the raw roll is relatively small, and the mill roll is operated in-line. It was considered to act as a buffer between the winder and the slitter rewinder operated offline. In some cases, there are even factories without storage capabilities. Therefore, in order not to stop the flow of operation, it is inevitable that the raw rolls to be produced have to be finished into the divided sheet rolls as the final products in sequence immediately after the temporary temporary placement.

It is too complicated for humans to make a slitter production plan. With this conventional production method, the desired delivery time which is just-in-time of the ordered product can be satisfied, and hundreds of orders can be specified. It was a difficult technique to directly assign the raw fabric rolls by combining the specifications and obtain a high product yield (the production ratio of the ordered product rolls to the raw fabric rolls).

[0007]

As a result, the quantity of products that can be ordered is directly assigned to the material roll and divided and finished, so that the quantity that can be shipped is extremely limited. After that, a large amount is sent to the product warehouse.

From the final products stored in a large quantity in the product warehouse, if the ones satisfying the market needs, that is, the small quantity of various products and the order receiving conditions that come in with just-in-time delivery are selected and shipped, all the products will be temporarily processed. Minimum of 10 in specifications
Even if you have a stock of books, 10 books x 1.2 million kinds = 1
A theoretical inventory requirement of 2 million. Of course, this quantity is an unrealistic fancy number.

Even in a realistic large-scale product warehouse, the largest one has a capacity equivalent to the production amount for at most one month or at most two months, and the above-mentioned hypothetical capacity of several tens of minutes. It is only one scale. Therefore, even with such a product warehouse, it is only halfway in the end,
The reality is that the percentage of products that can be shipped exactly in line with order conditions is extremely low.

As a measure against bitterness, a small slitter rewinder is used to reduce the yield, and even if the reprocessing of slits to match the product width and the winding length is vigorously carried out, the inventory will increase rather than disappear. In reality, if we approach the limit of our inventory capacity, we have no choice but to repeat the disposal process without profits several times a year by choosing a special processing customer who does not confuse the selling price. .

These accumulated inventory products having a low turnover ratio are the same liquid assets as cash and bills at the time of inventory settlement, and even ordinary assets are subject to taxation of 53%. And it causes a lot of loss such as loss, pressure on working capital, and management cost of stocking and warehousing, and the existence of this product inventory is a valuable source of revenue that is originally generated by normal sales activities. Nevertheless, it is actually a big factor that eats down profits and determines the superiority and inferiority of management.

The conventional sheet roll processing equipment and the manual production method as described above may be an engineering in which a machine having a unit function is installed in each process, or the machine itself may be incomplete. In addition, this is a natural consequence of having to rely on human experience and skill in production planning and operation management between processes.

[0013] Therefore, an object of the present invention is to provide a sheet roll processing facility capable of obtaining a wide variety of divided sheet rolls in just-in-time and with high yield.

[0014]

In order to achieve the above object, the present invention provides a production planning computer, a raw roll storage device for taking out a required raw roll based on a command from the production planning computer, and A slitter rewinder for processing the original roll taken out from the original roll storage device into the required divided sheet rolls based on a command from the production planning computer.

[0015]

In the present invention, the strip-shaped sheet for making the divided sheet roll is not processed and stored in the divided sheet roll as a product as in the conventional product warehouse, but is stored in the original roll storage device without being processed. It is stored as the original roll.

The computer for production planning stores the information about the individual original rolls stored in the original fabric roll storage device and the necessary information about the individual divided sheet rolls in each storage unit, and stores the stored individual information. Based on the information on the original roll and the information on the necessary individual sheet rolls, make an operation plan for the slitter rewinder, and instruct the original roll storage device to take out the required original roll based on this operation plan. , Command the slitter rewinder to take up the required divided sheet roll separately.

[0017]

Embodiments of the present invention will now be described with reference to the drawings. FIG. 1 is an explanatory view showing an embodiment of the present invention in a block form. In FIG. 1, 1 is a computer for production planning, 2 is a roll roll storage device, and 3 is a slitter rewinder.

The divided sheet roll 4, which is a product, is an intermediate product obtained by successively winding a belt-shaped sheet 5 (a plastic film in this embodiment) which is continuously molded and sent by a film forming machine (not shown) by a winder 6. Raw roll 7
And the roll roll 7 in the slitter rewinder 3
The strip-shaped sheet 5 is not rewound, cut into a required width, and wound by a required length. Then, the product is shipped as a product through a packaging process and the like.

The original fabric rolls 7 are successively supplied from the winder 6 to the original fabric roll storage device 2 and stored therein. The original roll storage device 2 has a sufficient amount corresponding to the processing capacity of the slitter rewinder 3 so that the original roll corresponding to the required divided sheet roll can be immediately supplied to the slitter rewinder 3 when necessary. The original roll 7 is stored.

The raw fabric roll storage device 2 stores a large amount of the raw fabric rolls 7 supplied from the winder 6 and stores the raw fabric rolls 7 on a support 8 and supports them in parallel at predetermined positions. And an original roll composed of an overhead crane or a self-propelled carriage for holding and moving the original roll 7 and storing it in an arbitrary storage position of the storage unit or taking it out from an arbitrary storage position of the storage unit. A transport mechanism 10 is provided. The original roll transport mechanism 10 includes a control computer 11
The original roll 7 stored in the storage position can be automatically taken out by moving to the designated storage position of the storage unit 9 under the control of the. The storage unit 9 of the original roll storage device 2 and the original roll transport mechanism 1
0 is not limited to the above-mentioned one, but is, for example, JP-A-3-1824.
As disclosed in Japanese Unexamined Patent Publication No. 08, etc., necessary ones such as one provided with a rack, one provided with a stacker crane, one having a hook attached to a circulating endless chain to support and store the original roll, etc. As long as it has a roll take-out function, its structure or form does not matter.

The control computer 11 always provides data relating to the original roll specifications such as individual sheet type, sheet thickness, sheet width and winding length for each original roll 7 stored in the original roll storage device 2. Data such as the storage position can be stored.

The slitter rewinder 3 supports the original fabric roll 7 taken out by the original fabric roll transport mechanism 10 and rewinds the strip-shaped sheet 5 to rewind the strip-shaped sheet 5 at a desired position. A slitter device 13 for dividing the slitter device 13 into a plurality of sheets, a sheet conveying portion 14 including the slitter device 13, and a winding portion 15 for winding the divided strip-shaped sheet 5 ′ into the divided sheet rolls 4.

The winding section 15, the sheet conveying section 14 including the slitter device 13, and the rewinding section 12 are controlled by the control computer 16 and when the divided strip-shaped sheet 5'is wound up by a required amount, the winding operation is performed. Is automatically stopped.

The slitter device 13 is disclosed in, for example, Japanese Patent Laid-Open No.
As disclosed in Japanese Laid-Open Patent Publication No. 1-142097, the cutting blade 13a for cutting the belt-like sheet 5 can be automatically positioned, and corresponds to a dividing position or a dividing width instructed by the control computer 16. Cutting blade 1 at the position
3a can be attached. If the cutting blade has a function of cutting a sheet, not only a mechanical one such as a sharp knife or round blade, a pair of shearing round blades but also ultrasonic waves and laser beams are used. Including those that have been done.

The control computer 16 controls not only the positioning of the slitter device 13 but also the winding section 15 in order to improve the equipment operating rate and the stability of the winding quality.
A function for automatically positioning and controlling a device for supporting the divided sheet roll 4 and a supporting device for each touch roller in contact with the divided sheet roll 4, and a mechanism for transporting the touch roller to the supporting device, mounting and collecting the touch roller. It is preferable to have a function of automatically controlling the operating conditions such as a winding tension and a touch pressure of the winding unit 15, a rewinding tension of the rewinding unit 12, and the like.

Since the production planning computer 1 is required to process a huge amount of data concerning, for example, daily order information, the capacity of the storage section is naturally large. However, since the control computer 11 of the original roll storage device 2 and the control computer 16 of the slitter rewinder 3 give priority to the control function of the device in real time, the capacity of the storage unit is usually small. Therefore, it takes time to directly exchange data between the control computers 11 and 16 and the production planning computer 1. Therefore, although not shown in the figure, it is effective to provide a relay computer in the middle between the two in order to smoothly and quickly perform mutual communication.

The production planning computer 1 has a winding specification such as sheet type, sheet thickness, divided sheet roll width (division width), winding length, and winding core size of each required divided sheet roll. Related data, quantity, delivery date, shipping date, etc. are input from the input device 1a at any time.

Further, the production planning computer 1 receives each data relating to each original roll specification stored in the control computer 11 of the original roll storage device 2, and each received data is referred to as an original. It is possible to store the information about the strip-shaped sheet in the storage unit for each original roll.

The production planning computer 1, based on the information about the required divided sheet rolls stored and the information about the belt-shaped sheets to be the raw material, which are stored so as to satisfy the delivery conditions and improve the yield and the operating rate as much as possible. It stores the procedure for making an operation plan for the slitter rewinder 3.

When formulating an operation plan, the production planning computer 1 first stores the required divided sheet rolls that need to be created in the meantime in order to make an operation plan for a certain period by giving top priority to meeting the delivery date. The information is searched from the available information, and the information is collected for production planning.

Then, in order to increase the yield, how to allocate the divided strip-shaped sheets of the product to be obtained to the strip-shaped sheets to be used is simulated by calculating various ways. Decide that the loss is as small as possible. Further, the operating rate is improved by planning so that the movement amount of the cutting blade 13a of the slitter device 13 can be reduced as much as possible when the product width is changed.

Thus, the production planning computer 1 is
A signal for designating the required original roll is output to the control computer 11 of the original roll storage device 2, and the control computer 16 of the slitter rewinder 3 outputs individual signals for each divided winding cycle. A signal for designating the winding specification including the width and the winding length of the sheet roll is output in the unit of divided winding cycle.

The control computer 16 of the slitter rewinder 3 instructs the slitter device 13 and the like to perform an operation based on the winding specification designated by the signal output from the production planning computer 1. As a result, in the slitter device 13, the cutting blade 13a comes to the division position corresponding to the command.

Further, the control computer 11 of the original roll storage device 2 controls the original roll transport mechanism 16 so as to take out the designated original roll based on the signal output from the production planning computer 1.

The embodiment of the present invention is not limited to the above-described embodiment shown in FIG. 1, and can be variously changed without changing the gist of the invention. For example, the operation plan procedure of the slitter rewinder stored in the computer for production planning can change the set value of the condition of the operation plan, change the content and sequence of the processing operation if the operation plan can be automatically created. May be. Further, the production planning computer sends a signal designating a winding specification such as a dividing position or a dividing width of the strip-shaped sheet, a winding length, and a necessary specification of the original roll based on the operation plan established by the computer to the data highway. Not only to send directly to the control computer of the roll roll storage device and slitter rewinder via the, but also to the terminal device,
The operation may be instructed to each machine by displaying the instruction content. In that case, for example, in the slitter rewinder, the operator sets the division position or division width of the strip-shaped sheet and the winding length based on the display. Also,
The original roll transport mechanism and the storage device may be operated semi-automatically or manually based on the setting operation by the operator. Further, the data forming the information about the required divided sheet rolls and the information about the original rolls that are input may change according to the design conditions of the system.

Further, the original roll may be a roll of a belt-shaped sheet other than a plastic film such as paper, a thin metal plate or the like, or may be an offline winder or a winder directly connected to a film forming machine. It may be made by another slitter rewinder.
In addition, the raw roll that is the target of the operation plan may be one that is scheduled to be manufactured by the time it is needed.

[0037]

According to the present invention, the computer for production planning uses the slitter rewinder based on the stored information about the individual original rolls stored in the original roll storage device and the necessary information about the individual divided sheet rolls. Therefore, it is not necessary to manufacture a large number of unordered split sheet rolls as in the past because an operation plan is set up. Therefore, the conventional product warehouse becomes unnecessary, and it is not necessary to store and take out a large amount of unordered divided sheet rolls in the product warehouse, and the number of workers for that purpose can be reduced. Moreover, since a large amount of unordered products do not sleep in the product warehouse, the yield is improved, and the productivity of the dropped raw materials, energy, etc. is significantly improved. In addition, the economic burden of taxation will be greatly reduced.

Further, the strip-shaped sheet for making the divided sheet roll is not processed into a divided sheet roll as a product and stored in a product warehouse as in the conventional case, but is not processed and is stored in a raw roll storage device. Since the original roll of the product is stored as it is, the original roll can be taken out and processed into a required width and length when necessary. The resulting lead time is greatly reduced. For example, it is possible to make a production plan on a day-by-day basis, and it is also possible to ship on the next day when an order is received.

Accordingly, it is possible to provide a split sheet roll processing equipment capable of obtaining a wide variety of split sheet rolls with just-in-time and high yield, and by using the equipment of the present invention, the production cost of split sheet rolls can be reduced. Significant savings can be made, and competition for winning orders can be advantageously developed in terms of cost and delivery time.

That is, the present invention is most characterized in that a large amount of semi-finished raw rolls are stored in the mill roll storage, and a production system is adopted in which the order specifications are assigned to the raw rolls. Further, according to the present invention, for example, even if at least one original roll is stocked for each combination of the type and thickness of the strip-shaped sheet, if 50 original rolls are stocked as semi-finished products, Depending on the quantity, first of all, with just-in-time delivery conditions to meet the market needs of any product specifications, and with integrated manufacturing and sales, we can receive orders for all specifications in the handling range, with a high combination yield, with a production plan of only ordered products. The prerequisites that can be met are satisfied.

In addition, the operation plan of the slitter rewinder, which is designed not by humans but by computers, complicates the number of orders and the types of products, resulting in hundreds of thousands to several hundreds.
Even if it reaches, 000,000, it is possible to formulate a production plan (95% to 99.5%) that always achieves a theoretical maximum product yield (production ratio of product rolls to original rolls). The difference in yield due to this manufacturing and sales system creates disparate Konuto competitiveness. In conventional factories, it is difficult to grasp the yield clearly because the management after it is stored in the product warehouse is unclear (reprocessing, inventory disposal, etc.), but this yield is estimated to be 80% to 85%. Estimated to be a percentage stop, resulting from the present invention 1
A product yield improvement of 0% to 15% will create a new cost competitiveness of 350 million to 500 million yen in one year for a production plant with annual output of 3.5 billion yen.

Further, the sheet roll processing equipment according to the present invention is a system using a computer, not a person skilled in the art, for production planning and operation management of each process device,
In that network, the numerical values of the products and information of all processes are managed in an integrated and accurate manner in real time, so the production and sales can be automatically managed up to the balance, which has the direct merit of manpower saving and There is no variation.

Further, by utilizing a mill roll storage for storing a large amount of original rolls, it is possible to reduce the frequency of lot switching of the film forming machine, and as a result, the effect of improving the yield on the upstream side becomes large. .

[Brief description of drawings]

FIG. 1 is an explanatory diagram for explaining an embodiment of the present invention.

[Explanation of symbols]

 1 Production planning computer 2 Raw roll storage device 3 Slitter rewinder 4 Divided sheet roll 7 Raw roll 13 Slitter device

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location B65H 35/02 9037-3F

Claims (1)

[Claims] 1. A production planning computer, a raw fabric roll storage device for taking out necessary raw fabric rolls based on instructions from the production planning computer, and the raw fabric roll storage device based on instructions from the production planning computer. Sheet roll processing equipment equipped with a slitter rewinder that processes the original roll taken out into the required divided sheet rolls.