JPH0721273A - Device for deciding charging order in manufacturing line - Google Patents

Abstract

PURPOSE:To decide proper charging order in accordance with the rule of charging order decision even by a layman operator. CONSTITUTION:Production condition data such as a kind and its quantity, etc., to be charged to a manufacturing line and process condition data such as a work rate, etc., are set by a data setting part 9, these kinds of condition data are processed in accordance with a standardizing condition consisting of the rule of charging order decision, etc., by a standardization processing part 10 and the charging order of the kind is decided. Moreover, whether or not the charging order is proper as against an evaluation reference value which is previously set by a lot adjusting part 11 is evaluated by the line work rate, a work operator load factor and a time designation delivery appointed date keeping rate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a manufacturing line loading sequence determining device for determining an appropriate loading sequence of products in a manufacturing line for assembly and cutting.

[0002]

2. Description of the Related Art For example, when making a schedule for a product assembly line, the order of loading parts and the lot size are determined. This decision is often made according to a predetermined rule suitable for each assembly line.

Therefore, according to such a method of determining the input order,
An operating operator who is familiar with the rules is required, and even if the operating operator determines the loading sequence, it takes time to make the determination.

Further, it is difficult to judge whether or not the obtained result of the feeding order is proper. Therefore, it is necessary to evaluate whether or not the result of the input order is appropriate.

[0005]

As described above, in order to determine the loading sequence for the assembly line, (a) a specialized operator who is familiar with the way is required, and it takes time to determine. (b) There is a part depending on the experience and intuition of the operating operator, and the method for determining the charging sequence is often not standardized, although the charging sequence is determined according to the determined rule. (c) It is not possible to evaluate whether the input order is proper. There is a problem.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a manufacturing line loading sequence determining apparatus which can determine an appropriate loading sequence in accordance with the rules for determining the loading sequence even if it is not a specialized operator.

[0007]

According to the present invention, there is provided a manufacturing line loading sequence determining apparatus for determining a loading sequence of a plurality of types of parts to be loaded into a manufacturing line, and production condition data consisting of at least products to be loaded into the manufacturing line, and Data setting means for setting process condition data consisting of at least the operating rate in the production line, and production condition data and process condition data set by this data setting means, and processing according to the leveling condition consisting of at least a rule for determining the input sequence And a leveling processing means for determining the order of loading a plurality of types of parts, and is a manufacturing line loading order determination device for achieving the above object.

Further, according to the present invention, in the above production line loading sequence determining apparatus, there is provided lot adjusting means for evaluating whether or not the loading order obtained by the leveling processing means is appropriate with respect to a preset evaluation reference value. And a manufacturing line input sequence determining device for achieving the above object.

In this case, the lot adjusting means sets at least the line operating rate, the work operator load rate, and the time designated delivery date keeping rate as the evaluation reference values, and the loading order obtained by the leveling processing means has these evaluation reference values. If the condition check unit that evaluates whether or not the condition value is satisfied and the evaluation result by this condition check unit are not satisfied, the lot sizes and the number of productions of a plurality of types are changed, and the changes are made to the leveling processing means. It has a lot changing unit for handing over.

[0010]

By providing such means, the data setting means sets the production condition data such as a plurality of products to be put into the manufacturing line and the quantity thereof, and the process condition data such as the operating rate. The leveling processing means performs processing in accordance with leveling conditions including rules for determining the order of loading and the like, whereby the loading order of the product types is determined.

Furthermore, whether the order of loading is appropriate for the lot adjustment conditions preset by the lot adjusting means is determined by, for example, the line operation rate, the work operator load rate, and the time designated delivery date keep rate as evaluation reference values. An evaluation is done.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a block diagram of a production line loading sequence determination device. A production condition data memory 3, a process condition data memory 4 and a lot adjustment condition data memory 5 are connected to the main control unit 1 via an input / output unit 2, and a CRT display 7 is connected via another input / output unit 6. And a keyboard 8 are connected.

Among them, the production condition data memory 3 stores, as the production condition data, the product type for assembling the product, the quantity thereof, and the minimum lot, and the process condition data memory 4 stores the operating condition as the process condition data. , Operation rate, process machining / assembly time, worker charge, work time, setup product type, setup time are stored.

Further, the lot adjustment condition data memory 5 includes
A line operating rate, a work operator load rate, and a time designated delivery date keep rate are stored as evaluation reference values for evaluating whether or not the determined loading sequence is appropriate. The time-specified delivery date keep rate is a keep rate of whether or not n pieces of a certain product are produced every m hours.

On the other hand, the data setting unit 9 and the leveling processing unit 10
Also, a lot adjusting unit 11 is provided, and these are the main control unit 1.
It is operated by the command issued from.
The data setting unit 9 has a function of reading the production condition data from the production condition data memory 3, reading the process condition data from the process condition data memory 4, and setting the condition data.

The leveling processing unit 10 receives the production condition data and the process condition data set by the data setting unit 9, processes these condition data at least in accordance with the leveling conditions including the rules for determining the order of introduction, and It has a function of determining the lot size of a product type, the number of productions, and the order of input.

The rule for determining the input order will be described below. In this rule, as shown in FIG. 2, (a) the order in which the number of productions is large and the order in which the production frequency is small (b) the starting point is the center, Last (c) If each product interferes in ordering, the placement position (front and back) and product pattern of that product, for example product A →
It has a product type B → product type C.

The lot adjusting section 11 evaluates whether or not the input sequence obtained by the leveling processing section 10 is appropriate for a preset lot adjusting condition, and displays the result on the CRT display 7. Is to have.

Specifically, the line operating rate, the work operator load rate, and the time designated delivery date keeping rate are set as evaluation reference values, and the charging sequence obtained by the leveling processing means satisfies the condition values of these evaluation reference values. If the condition check unit 12 that evaluates whether or not to perform the evaluation is not satisfied, the function of changing the lot size and the number of times of production of each product type and passing the changed contents to the leveling processing unit 10 And a lot changing unit 13 having a.

Next, the operation of the apparatus constructed as described above will be described when it is applied to the assembly line shown in FIG. This assembly line consists of the following prerequisites.

(A) The number of lines is one, first in /
First out (FIFO). (b) The line consists of multiple facilities.

(C) The processing / assembling time of equipment depends on the product type. (d) Workers perform handling (Hg) between facilities, and the setup time does not depend on the product type.

(E) The worker also carries out the work in the normal process, and the work time varies depending on the product type. Actually, the assembly line has each of the equipments M / C1 to M / C3 and the inspection process, and the worker is from the equipments M / C1 to
I am in charge of handling work and inspection process.

Next, the operation when applied to the above assembly line will be described with reference to the overall flow chart for determining the loading sequence shown in FIG. (1) First, the data setting unit 9 reads the production condition data from the production condition data memory 3 and the process condition data from the process condition data memory 4, and sets these condition data.

Concretely, as the production condition data, as shown in FIG. 5, the quantity and the minimum lot are set for each kind A, B, C, D. On the other hand, in the process condition data, the operating rate and the operating time zone are set as shown in FIG. Of these, the operating hours consist of start time and end time.

As the process condition data, the work in charge of the work operator shown in FIG. 7, in this case, the handling work and the inspection process are set. Further, as shown in FIG. 8, as the process condition data, the processing / assembling time for each equipment M / C1 to M / C3 and each product type A to D in the inspection process is set.

Further, as the process condition data, setup items A to D and setup time are set as shown in FIG. (2) Next, the operation of the leveling processing unit 10 will be described with reference to the flow chart of the leveling processing shown in FIG.

(A) First, lot determination # 1 is performed.
In this case, the operation operator operates the leveling key on the keyboard 8 to select either the quantity or the load. The leveling processing unit 10 determines the number of productions and lot size according to the selected quantity or load, and displays the result on the CRT display 7.

At this time, when the quantity is selected, the leveling processing unit 10 determines the number of productions and the lot size according to the relationship of lot size = minimum lot number of productions = quantity / lot size.

When the load is selected, the leveling processing unit 10 obtains the load factor (load factor = load / load meter) from the load (load = quantity * line takt) of each product and determines the minimum lot. Restrain the number of production and the lot size corresponding to the load. The number of productions = load factor * minimum production count total lot size = quantity / number of productions.

If the production count and lot size displayed on the CRT display 7 are defective, the operator operates the keyboard 8 to manually correct the production count and lot size.

FIG. 11 shows the results of the number of productions and lot sizes for each product type A to D when the load is selected by the leveling key. (B) Next, ordering # 2 is performed.

In this case, the operating operator operates the keyboard 8 to set the ordering priority, rule, and product type pattern, and the leveling processing unit 10 determines the product input order based on these settings. This result is C
It is displayed on the RT display 7.

In this case, the priority is selected according to any one of the rule, the rule + type pattern, and the type pattern. Further, in the rule and product type pattern setting, as shown in FIG. 2, the number of times of production, the allocation base point, the arrangement position in the case of product type interference, and the pattern in which the product types are arranged are set.

Here, the operation of the leveling processing unit 10 when each priority is selected will be described. (a) When the rule is selected as the priority, the allocation interval Da of each product type A to D is calculated from the production frequency meter, Da Da = the production frequency meter / the production frequency, and the type with the high production frequency or the low production frequency according to the content of the rule setting. Targets are assigned according to product type and assigned to the ranking. This allocation is performed from a certain order according to the setting base point until the number of allocation reaches the number of times of production.

That is, if the base point is the first, 1, D
a, 2Da, ... in the order Da / 2, (D
a / 2) + Da, (Da / 2) + 2Da, ... in that order, and in the last case, Da, 2Da, 3Da ,.

If a product type has already been assigned to that rank, it is assigned to the front or back of that rank in accordance with the response at the time of interference. (b) When the rule + product type pattern is selected as the priority, after assigning all the product types to the order by the same process as in the case of the above rule, two or more product types in the product type pattern are continuously assigned. If there is a rank, the product patterns are rearranged within the rank.

(C) When the product type pattern is selected as the priority, the product type patterns are assigned in order until each product reaches the number of times of production. This is possible as long as two or more kinds of continuous patterns are formed. If there are any varieties in the varieties pattern, those varieties are assigned at the end of the rank, and subsequently varieties not in the variety patterns are assigned until the number of productions is reached.

Through the above processing, the leveling processing unit 10 determines the order of loading the respective products A to D. FIG. 12 shows an example of the result, and this input order is the result of selecting the rule + type pattern with respect to the lot determination result shown in FIG. (3) Next, the operation of the lot adjusting unit 11 will be described with reference to the flow chart of the lot adjusting process shown in FIG.

The lot adjusting section 11 uses the line operation rate as an evaluation reference value for evaluating whether the loading sequence is appropriate from the lot adjusting condition data memory 5 as condition setting # 3.
Read out and set the work operator load factor and time designated delivery date keep factor.

Next, the condition checking section 1 of the lot adjusting section 11
2 evaluates whether or not the input sequence obtained by the leveling processing unit 10 in the process # 4 satisfies each of the above evaluation reference values.

In this case, the condition check unit 12 obtains the following time value and condition item and displays them on the CRT display 7. That is, <calculation formula of each item for rank i> (a) Assembly time = machining time per piece (line tact)
* Number of lots where line tact = maximum value of processing time of equipment and processing time of operator (b) Occupied time = assembly time / operating rate (c) Setup = setup of operator for next product type Time (d) Work operator time = (worker handling time + work time) * lot + setup time (e) Operating time = sum of occupied time (1 to i) + sum of setup time (1 to i-1) (f) Work operator load factor (i) = worker time (1 to i)
Sum of / (number of workers * operating time) * 100 [%] (g) Line operating rate (i) = sum of assembly time (1 to i) + operating time * 100 [%] (h) Time-specified delivery type Assuming that the production number of a is p after m minutes, the delivery rate keep rate is (p / n) * 100 [%] (n: number of delivery times specified after m minutes). If there is a defect as a result of the evaluation by the condition checking unit 12, the operator's operation of the keyboard 8 manually corrects the order of loading, moves the unachieved plan into the plan, or collects lots.

FIG. 14 is a view showing the result of such lot adjustment. The order of loading, product type, lot size, start: completion time, occupation time, setup time, worker time, work operator load in the operating time zone. The rate and line availability are displayed.

At the same time, as shown in FIG. 15, the unachieved product types outside the operating hours, lot size, occupation time, assembly time, setup time, worker time, work operator load factor, line operation rate are In addition, the rate of delivery of the designated product within a certain period of time is displayed based on the evaluation result of the designated delivery time.

The lot summary # 5 is based on the lot changing section 1
The lot size is changed manually or automatically according to 3. In the case of manual operation, some of the varieties of the same varieties that are assigned to a plurality of ranks by hand correction are put together into one, or the varieties of a certain rank are divided and assigned. Then, the lot changing unit 13 passes the changed allocation order to the condition checking unit 12.

In the case of automatic processing, a method of selecting a target product type for grouping is set by setting a lot grouping rule. Here, small / large lot size and small / large production number are combined with priorities. According to this, the target product type is determined, and a value obtained by multiplying the lot size of the product type by an integer is set as a new lot size, and the number of times of production is calculated from the quantity and the lot size. Then, the lot changing unit 13 passes the changed lot size and the number of productions to the leveling processing unit 10.

As described above, in the above-described embodiment, the production condition data such as the type and quantity of the product to be introduced into the assembly line and the process condition data such as the operating rate are set, and the condition data is used as a rule for determining the order of introduction. Since the processing order is determined according to the leveling condition consisting of, the proper charging order can be determined in accordance with the rules for determining the charging order even if the operator is not a specialized operator.

Further, it is possible to evaluate whether or not the charging sequence is proper as a line operating ratio, a work operator load factor, and a time designated delivery date keeping ratio as evaluation reference values, and finally to determine an optimum charging sequence.

The present invention is not limited to the above-mentioned one embodiment, and may be modified within the scope of the invention. For example, not only the assembly line but also the cutting line can be applied.

[0050]

As described above in detail, according to the present invention, it is possible to provide a manufacturing line loading sequence determining apparatus which can determine an appropriate loading sequence in accordance with the rules for determining the loading sequence without being a specialized operator.

[Brief description of drawings]

FIG. 1 is a configuration diagram showing an embodiment of a production line loading sequence determination device according to the present invention.

FIG. 2 is a diagram showing an ordering rule and a product type pattern in the same apparatus.

FIG. 3 is a configuration diagram of an assembly line applied to the apparatus.

FIG. 4 is an overall flow chart of a throwing order determination process of the apparatus.

FIG. 5 is a diagram showing production condition data in the apparatus.

FIG. 6 is a view showing an operation rate and an operation time zone in the process condition data in the apparatus.

FIG. 7 is a diagram showing the work in charge of the worker in the process condition data in the apparatus.

FIG. 8 is a view showing machining / assembly time in the process condition data in the same apparatus.

FIG. 9 is a diagram showing setup time in the process condition data in the apparatus.

FIG. 10 is a flowchart of leveling processing in the same apparatus.

FIG. 11 is a diagram showing the number of productions and lot size obtained by the leveling process in the same apparatus.

FIG. 12 is a view showing a loading order determined by the apparatus.

FIG. 13 is a flowchart of lot adjustment processing in the same apparatus.

FIG. 14 is a diagram showing a result of lot adjustment processing in the same apparatus.

FIG. 15 is a diagram showing a result of lot adjustment processing in the apparatus.

[Explanation of symbols]

1 ... Main control unit, 2, 6 ... Input / output unit, 3 ... Production condition data memory, 4 ... Process condition data memory, 5 ... Lot adjustment condition data memory, 7 ... CRT display, 8 ... Keyboard, 9 ... Data setting unit 10 ... Leveling processing unit, 11 ...
Lot adjusting section, 12 ... Condition checking section, 13 ... Lot changing section.

Claims (3)

[Claims] 1. A manufacturing line loading sequence determining apparatus for determining a loading sequence of a plurality of types of parts to be loaded into a manufacturing line, wherein production condition data including at least the plurality of types of parts to be loaded into the manufacturing line and at least the manufacturing line. The data setting means for setting the process condition data consisting of the operating rate, the production condition data and the process condition data set by the data setting means, and at least processing them according to the leveling condition consisting of the rules for determining the input sequence. A manufacturing line loading sequence determination device, comprising: a leveling processing means for determining a loading sequence of products. 2. A manufacturing line loading sequence determining device for determining a loading sequence of a plurality of types of components to be loaded on a manufacturing line, wherein at least the manufacturing condition data including at least the plurality of types of components to be loaded on the manufacturing line. Data setting means for setting the process condition data consisting of the operating rate in the line, and the production condition data and process condition data set by the data setting means, and processing at least according to the leveling condition consisting of the rules for determining the input sequence. A leveling processing means for determining a loading order of the plurality of types of parts, and a lot adjusting means for evaluating whether or not the loading order obtained by the leveling processing means is appropriate for an evaluation reference value. A manufacturing line loading sequence determining device characterized by: 3. The lot adjusting means sets at least a line operating rate, a work operator load rate, and a time designated delivery date keeping rate as evaluation reference values, and the loading order obtained by the leveling processing means is a condition of these evaluation reference values. A condition check unit that evaluates whether a value is satisfied, and if the evaluation result by this condition check unit is not satisfied, the lot size and the number of productions of each product type are changed, and the changed contents are passed to the leveling processing means. The manufacturing line loading sequence determination device according to claim 2, further comprising: