JPH0761535A - Method for delivering parts to be supplied to manufacture line - Google Patents

Abstract

PURPOSE:To carry parts efficiently, which are housed in an automatic warehouse, to a manufacture line. CONSTITUTION:Parts boxes 2, 3, in which parts to be required for a manufacture line 8 are housed, are delivered by a truck 1 from an external factory per a predetermined time, and sort of parts and the number of parts boxes 2, 3 are registered on the basis of signboards 2a, 3a for showing various information of delivered parts, which are housed in the parts boxes 2, 3, and thereafter, these parts boxes 2, 3 are housed in an automatic warehouse 11. The signboards 2a, 3a, which are removed per each time of using parts of the parts boxes 2, 3 in a manufacture line 8, are recovered, and parts boxes 2, 3 housed in the automatic warehouse 11 are delivered by the number of recovered signboards 2a, 3a.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of delivering parts to be supplied to a production line.

[0002]

2. Description of the Related Art Conventionally, as a stock management method, a so-called kanban system has been adopted in factories, in which a required product is produced in a required amount in a required time and parts are procured, and a product is manufactured. When this kanban system is completely performed, there is no inventory in the production process and the distribution process, and the cost for inventory can be saved.

FIG. 2 shows a system for supplying a parts box for accommodating parts by the Kanban system. The transportation means such as the truck 51 is a parts box 52 for storing parts ordered in advance,
53 (At this time, the parts box 52 is 8 boxes, and the parts box 53 is 16 boxes.
The box is placed on the pallet 54 and delivered. The factory side conveys the delivered parts boxes 52 and 53 together with the pallet 54 to the parts shelf 56 provided near the manufacturing line 55.

First, the parts box 52 is arranged on the parts shelf 56.
The second storage shelf 56b in which the storage shelf 56a and the component box 53 are arranged
Is provided. The first and second storage shelves 56a, 5
The component boxes 52, 52 can be arranged in the 6b at a maximum of 6 boxes.

In this case, the component box 5 is placed in the first storage shelf 56a.
2 is replenished with 2 boxes, and the component box 53 is replenished with 4 boxes in the second storage rack 56b. Therefore, the number of component boxes 52 on the pallet 54 that could not be replenished is 6, and the number of component boxes 53 is 12.

The remaining parts box 52 that cannot be replenished,
53 is placed in a temporary storage area provided in the factory.
Then, the component boxes 52, 53 placed in the first and second storage shelves 56a, 56b of the component shelf 56 are placed in the temporary storage area so that the component boxes 52, 53 are not in a shortage state (dangerous stock),
53 is conveyed again together with the pallet 54, and the first and second storage shelves 5
6a and 56b are replenished with the parts boxes 52 and 53.

On the other hand, the worker 57 of the manufacturing line 55 manufactures a product using the parts housed in the parts boxes 52 and 53. At this time, when using the first part of the parts box 52, 53, the kanban 5 placed in each of the parts box 52, 53
2a and 53a are removed and inserted into the pre-specified insertion portions 59a and 59b of the child post 59. On the kanbans 52a and 53a, various kinds of information such as part numbers, manufacturing factories, and the number of parts are indicated by numbers, bar codes, and the like.

In addition, at the time of loading, the kanbans 52a and 53a are loaded into the loading portion 59a in which the lamp 60 is lit. At this time, two parts boxes 52 are used and a parts box 53 is used.
Since four boxes are used, two kanbans 52a and four kanbans 53a are loaded in the loading section 59a.

The Kanban 5 inserted in the child post 59
2a and 53a are collected by a collecting member at predetermined time intervals, and are thrown into a parent post 61 for collecting them collectively. The parent posts 61 also have input parts 62a, 62
b is provided and the insertion portion 6 on the side where the lamp 63 is lit
It is designed to be put into 2a and 62b. At this time,
The kanban 52 is placed in the loading portion 62a where the lamp 63 is lit.
a and 53a are thrown in and collected collectively.

The collected kanbans 52a and 53a read the types of parts used by the bar code reader 64, the number of parts, etc. and store them in a computer (not shown), and sort the kanbans 52a and 53a by factory. The sorted kanbans 52a and 53a are handed at the time of delivery of parts of the truck 51 corresponding to the factory.

Then, the truck 51 takes the handed kanbans 52a and 53a back to the factory, and the factory manufactures the parts corresponding to the part number based on the kanbans 52a and 53a by the used number, and again the truck 51. To be shipped.

By the way, the first and second storage shelves 56a and 56b.
After the parts boxes 52 and 53 are refilled, the remaining parts boxes 52 and 53 that cannot be refilled are placed together with the pallet 54 in the temporary storage area of the factory. However, some factories may not be able to provide a temporary storage space because the site is small. Then, the remaining parts box 52 that could not be replenished,
There is a problem that 53 cannot be temporarily stored together with the pallet 54.

As a countermeasure against this, the applicant of the present invention has stored the remaining parts box 5 that could not be replenished in the first and second storage shelves 56a and 56b.
We have proposed a system that stores 2, 53 together with pallets 54 in an automated warehouse.

This system is shown in FIG. Truck 51
Thus, the eight component boxes 52 and the sixteen component boxes 53 are delivered while being placed on the pallet 54. This parts box 5
The barcodes of the kanbans 52a and 53a put in every 2 and 53 are inputted into the barcode reader 71 of the input processing device 70.
And input the number of delivery boxes 72 and the number of delivery boxes 72 and 53 of the same type of component boxes 52 and 53, respectively. Then, the types and the number of boxes of the component boxes 52 and 53 are stored in the inventory management device 67.

The registered parts boxes 52 and 53 are conveyed to the parts shelf 56 of the manufacturing line 55 together with the pallet 54 and are replenished to the first and second storage shelves 56a and 56b as much as possible. In this case, two parts boxes 52 are replenished, and a parts box 53 is added.
Will be replenished with 4 boxes. Therefore, the remaining parts box 52 that cannot be replenished becomes 6 boxes, and the parts box 53 becomes 12 boxes. These parts boxes 52 and 53 are stored in the automatic warehouse 73 together with the pallet 54.

On the other hand, the worker 57 of the manufacturing line 55 manufactures a product by using the parts accommodated in the parts boxes 52 and 53. At this time, when using the first part of the parts box 52, 53, the kanban 5 placed in each of the parts box 52, 53
2a and 53a are removed and put into the kanban post 74. At this time, two parts boxes 52 are used and a parts box 53 is used.
Since four boxes are used, two kanbans 52a and four kanbans 53a are put in the kanban post 74.

Further, the kanbans 52a and 53a collected by the collection staff at every predetermined time are used by the input device 75.
The number of the Kanbans 52a and 53a of the same type is input by the input key of the used number input device 66. The input-processed kanbans 52a and 53a are sorted by factory by the sorting machine 68 and handed to the driver of the truck 51 in the same manner as above.

On the other hand, the kanbans 52a and 53a input by the use input device 75 are output to the inventory management device 67. Then, the inventory management device 67 receives the kanbans 52a, 53a input by the use input device 75 from the type-specific component boxes 52, 53 input by the input processing device 70.
The component boxes 52 and 53 corresponding to the above are subtracted, and the number of remaining component boxes 52 and 53 is managed as the inventory number of the component boxes 52 and 53 stored in the automatic warehouse 73.

[0019]

Here, the recovery time of the kanbans 52a and 53a put into the kanban post 74 is basically based on the time when the truck 51 delivers the parts to the factory. For example, if the truck 51 delivers parts four times within one day (8 hours), the kanbans 52a and 53a may be collected every two hours.

Further, it is assumed that the component box 53 arranged on the second storage rack 56b becomes empty sooner than the component box 52 arranged on the first storage rack 56a becomes empty. At this time, it is possible to arrange the component box 53 in the second storage rack 56b by 6
The number of boxes in the dangerous stock that is insufficient in the number of parts boxes 53 is 2
A box. Then, the time required from 6 boxes to 2 boxes is 70 minutes.

In this case, if the kanbans 52a and 53a are collected according to the delivery time of the truck 51 and the inventory of the automatic warehouse 73 is managed, the parts box 53 arranged on the second storage rack 56b becomes insufficient. Therefore, in consideration of the delivery time of the truck 51, the kanbans 52a and 53a are collected every hour.

Then, based on the information of the kanbans 52a and 53a input by the use input device 75, the inventory management device 67 manages the inventory number of the component boxes 52 and 53 stored in the automatic warehouse 73. After that, the parts boxes 52 and 53 are delivered together with the pallet 54 from the automatic warehouse 73, and the first and second storage shelves 5
6a, 56b. After the transported component boxes 52, 53 are replenished in the first and second storage shelves 56a, 56b, the component boxes 52, 53 that cannot be replenished are stored in the automatic warehouse 73 again together with the pallet 54.

By the way, the first and second storage shelves 56a and 56b.
When replenishing the parts boxes 52 and 53, the parts boxes 52 and 53 are conveyed from the automatic warehouse 73 together with the pallet 54, and the parts boxes 52 and 53 that cannot be replenished are stored in the automatic warehouse 73 again.

Therefore, the first and second storage shelves 56a, 56b
Each time it is replenished, it is necessary to convey the component boxes 52, 53 which cannot be replenished together with the pallet 54, so that there is a problem that the conveyance efficiency of the component boxes 52, 53 is poor.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a parts delivery method for supplying parts stored in an automated warehouse to a production line capable of efficiently carrying the parts. To provide.

[0026]

In order to solve the above problems, according to the present invention, the necessary parts are delivered from the external factory at the production line at predetermined time intervals determined by the transportation means.
After registering the type and number of parts based on Kanban showing various information of attached parts for each delivered part, this part is stored in the automated warehouse and removed every time the part is used on the manufacturing line. The gist of this is to collect the rehabilitation kanbans and to pay out the number of parts stored in the automated warehouse based on the number of the rehabilitated kanbans.

[0027]

According to the present invention, the required parts are delivered by the transportation means from the external factory at predetermined time intervals on the production line. The type and number of parts are registered based on Kanban showing various information of delivered parts. Store the registered parts in the automated warehouse. Then, each time a part is used in the manufacturing line, the kanban that is removed is collected, and the number of parts based on the collected kanban is delivered from the automated warehouse, and the part is delivered to the manufacturing line.

[0028]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment of the present invention will be described below with reference to FIG. The truck 1 as a transportation means transports the parts boxes 2 and 3 containing the parts from the external factory to the delivery destination factory with the parts boxes 2 and 3 placed on the pallet 4. In the present embodiment, the truck 1 delivers the parts boxes 2 and 3 four times within eight hours a day, that is, every two hours. In addition, the component box 2 placed on the pallet 4
Is 8 boxes and the parts box 3 is 16 boxes. Then, the kanbans 2a and 3a indicating various kinds of information such as the type of parts, the manufacturing factory that manufactured the parts, and the number of the parts to be housed are put in each of the parts boxes 2 and 3 or the outside of the parts boxes 2 and 3. It is fitted on the side. The various information shown on the kanbans 2a and 3a is represented by numbers and bar codes.

An input processing device 5 as information input means is installed in the delivery destination factory. This input processing device 5
Input the number of boxes to be delivered, which has a bar code reader 6 that reads the bar codes of the kanbans 2a and 3a, and an input key that inputs the number of parts boxes 2 and 3 containing the same kanbans 2a and 3a. And machine 7.

Therefore, when the barcode of the kanbans 2a and 3a is read by the barcode reader 6, the delivery box number input device 7 has the same kanban 2 as the read barcode.
Since the system asks how many parts boxes 2 and 3 containing a and 3a are, enter the number of boxes with the input key.

An automatic warehouse 11 is provided in the factory. In the automatic warehouse 11, the component boxes 2 and 3 registered for delivery processing by the input processing device 5 are pallets 4
Everything is stored.

An inventory management device 12 as inventory management means is provided near the automated warehouse 11. The inventory management device 12 stores the type of parts and the number of parts boxes 2 and 3 input by the bar code reader 6 and the delivery box number input device 7 of the input processing device 5 for each type of parts. ing.

Further, a manufacturing line 8 for assembling the product is provided at the delivery destination factory. The production line 8
A component shelf 9 for arranging the component boxes 2 and 3 that have been delivered by the input processing device 5 is provided in the vicinity of. The component shelf 9 is provided with a first accommodation shelf 10a for accommodating the component box 2 and a second accommodation shelf 10b provided on the upper part of the first accommodation shelf 10a for arranging the component box 3. . In the present embodiment, the first and second storage shelves 10a, 10
The component boxes 2 and 3 can be arranged in b up to a maximum of 6 boxes. A return shelf 10c for returning the empty component boxes 2 and 3 is provided below the first storage shelf 10a.

On the other hand, the worker 13 who carries out the manufacturing work on the manufacturing line 8 manufactures products by using the parts in the parts boxes 2 and 3 arranged in the first and second storage shelves 10a and 10b of the parts shelf 9. At this time, when using the first parts stored in the parts boxes 2 and 3, the kanbans 2 a and 3 a put in the parts boxes 2 and 3 are put into the kanban post 14.

Further, the kanbans 2a and 3a put into the kanban post 14 are collected by the collecting staff at predetermined time intervals, and the kanbans 2a and 3a are collected by the use input processing device 15 as the use information input means. Is designed to be read. The use input processing device 15 includes a bar code reader 16 for reading the bar codes shown on the kanbans 2a and 3a, and a use number input device having an input key for inputting how many kanbans 2a and 3a of the same type are present. It is composed of 17 and.

In this embodiment, the collection time for the collection staff to collect the kanbans 2a and 3a put into the kanban post 14 is set as follows. For example, when 6 parts boxes 2 and 3 are supplied to the first and second storage shelves 10a and 10b and the parts in the parts boxes 2 and 3 are used, the parts in the parts box 3 are faster. It is assumed that the used empty space of the second storage rack 10b becomes faster.

In this case, if it takes 70 minutes from the state in which the component boxes 3 are completely replenished in the second storage rack 10b to 2 boxes which become dangerous stock, it is 2 in the truck 1.
It is impossible to collect the kanbans 2a and 3a according to each hourly delivery.

Therefore, in this case, considering the balance between the delivery time of the truck 1 every two hours and the time until the parts box 3 becomes a dangerous stock, the kanbans 2a and 3a are collected every hour. Has become. Further, if it takes 40 minutes to complete the second storage rack 10b from the state where 6 boxes are completely replenished to the second box that becomes a dangerous stock, it takes 40 minutes to collect the kanbans 2a and 3a. The kanbans 2a and 3a are collected every 30 minutes with an allowance.

Therefore, when the bar code shown in the kanbans 2a and 3a collected, for example, every one hour is read by the bar code reader 16, the number-of-uses input device 17 has the same kanbans 2a and 3a as the read bar code. You will be asked how many are there, so enter the number with the input key.

Further, after the use input processing device 15 performs the use input process of the kanbans 2a and 3a, the sorting device 1
It is designed to be sorted according to the external factory by 8. Kanbans 2a and 3a sorted by factory are handed to the truck driver who delivers the parts boxes 2 and 3 every two hours.

Then, the driver brings back the kanbans 2a, 3a handed over to the factory, manufactures parts based on the kanbans 2a, 3a, and installs the kanbans 2a, 3a in parts boxes 2, 3 respectively. Put it in and transport it to the factory again.

On the other hand, the use input device 15 is the inventory management device 1.
It is connected to 2. Then, the inventory management device 12 is adapted to be input with the type of parts and the number of kanbans 2a, 3a thereof inputted by the bar code reader 16 and the number-of-uses input device 17 of the use input processing device 15. .

Further, the inventory management device 12 determines the number of parts boxes 2 and 3 stored for each type of parts based on the input from the input processing device 5 and the type of parts based on the input from the use input device 15. Stored parts boxes 2 and 3 (Kanban 2a,
The number of 3a) is subtracted.

Then, the inventory management device 12 sets the number of the component boxes 2 and 3 stored for each type of the deducted components as the inventory number of the component boxes 2 and 3 stored in the automatic warehouse 11. It is supposed to be managed.

Further, the inventory management device 12 is adapted to display how many parts boxes 2 and 3 have been used based on the information of the kanbans 2a and 3a input from the use input processing device 15 every hour. There is. The number of boxes that can be replenished to the first and second storage shelves 10a and 10b is the same as the number of used boxes of the component boxes 2 and 3.

Therefore, the transfer operator, along with the pallet 4, puts the parts boxes 2 and 3 displayed on the inventory management device 12 in the automatic warehouse 11
From the pallet 4, the used parts boxes 2 and 3 are transferred from the pallet 4 to the used parts boxes 2 and 3
Are replenished to the first and second storage shelves 10a and 10b of the manufacturing line 8.

Now, from the external factory, the truck 1 delivers the eight component boxes 2 and the sixteen component boxes 3 mounted on the pallet 4. Then, the bar code shown in the Kanban 2 a contained in one component box 2 is read by the bar code reader 6 of the input processing device 5. Then, the number-of-delivery-boxes input device 7 asks how many parts boxes 2 contain the Kanban 2a which is the same information as the information based on the barcode. Therefore, it is instructed that there are eight boxes by operating the input keys of the delivery box number input device 7.

Similarly, the bar code shown in the Kanban 3a contained in one component box 3 is read by the bar code reader 6 of the input processing device 5. Then, the Kanban 3a becomes the same information as the information based on the barcode.
Enter the number of boxes to be delivered 7
Asks. Therefore, it is instructed that the number of boxes is 16 by operating the input key of the delivery box number input device 7.

Then, the inventory management device 12 stores the number of the component boxes 2 and 3 for each component type based on the input from the input processing device 5. Further, the parts boxes 2 and 3 that have been subjected to the delivery registration processing are stored in the automatic warehouse 11 together with the pallet 4.

In the production line 8, the worker 13 uses the parts box 2,
3. Manufacture a product using 3 parts. At this time, when the first parts in the parts boxes 2 and 3 are used, the kanbans 2a and 3a put in the parts boxes 2 and 3 are put into the kanban post 14. In this case, the Kanban post 14 has a parts box 2
2 boxes of kanban 2a and 4 boxes of kanban 3a of parts box 3 are placed. In addition, the first and second kanbans 2a and 3a corresponding to the number of kanbans 2a and 3a put into the kanban post 14 are provided.
The storage shelves 10a and 10b have a space in which the component boxes 2 and 3 can be replenished.

On the other hand, the kanbans 2a and 3a put into the kanban post 14 are collected by the collecting staff every hour, and the bar codes of the collected kanbans 2a and 3a are used by the bar code reader 16 of the input processing device 15. Read. In addition, the number of kanbans 2a and 3a of the same type is indicated by the input key of the used number input device 17. In this case, the kanban 2a is instructed to have two sheets, and the kanban 3a is instructed to have four sheets.

The inventory management device 12 is a use input processing device 15
The number of kanbans 2a and 3a for each type of the components input from is subtracted from the number of the component boxes 2 and 3 for each type of the components input from the input processing device 5. At this time, the number of component boxes 2 input from the input processing device 5 to the inventory management device 12 is eight, and the number of the component boxes 3 is sixteen. Further, there are two kanbans 2a corresponding to the parts box 2 input from the use input processing device 15,
The number of Kanbans 3a corresponding to the parts box 3 is four.

Therefore, the inventory management device 12 is provided with 8 of the parts box 2.
Two pieces of the Kanban 2a are subtracted from the box to make the parts box 2 into 6 boxes, and four pieces of the Kanban 3a are subtracted from 16 boxes of the parts box 3 to make 12 parts box. Then, the number of the component boxes 2 and 3 becomes the number of stocks stored in the automatic warehouse 11, and the stock management device 12 manages the number of stocks.

Further, the inventory management device 12 determines how many parts boxes 2 and 3 are arranged on the first and second storage shelves 10a and 10b based on the number of kanbans 2a and 3a input from the use input processing device 15. Shows whether it has been used. In this case, it is displayed that the parts box 2 is 2 boxes and the parts box 3 is 4 boxes.
Based on this display, the parts boxes 2 and 3 together with the pallet 4 are delivered from the automated warehouse 11, and the parts boxes 2 and 3 are moved to a forklift or the like by the number of boxes and conveyed to the first and second storage shelves 10a and 10b.

The two component boxes 2 and the four component boxes 3 thus conveyed are all replenished in the first and second storage shelves 10a and 10b, respectively. Therefore, the number of the component boxes 2 and 3 is determined based on the kanbans 2a and 3a put into the kanban post 14, and the determined number of the component boxes 2 and 3 is determined from the automatic warehouse 11 to the first and second storage shelves 10a. Since it is transported to 10b, it is not necessary to bother to transport the component boxes 2 and 3 that could not be replenished to the automatic warehouse 11 and return them to the automated warehouse 11 to reload them again.

As a result, based on the kanbans 2a and 3a put into the kanban post 14, the parts boxes 2 and 3 are transferred from the automatic warehouse 11 to the first and second storage shelves 10a and 10b, and the transferred parts boxes are transferred. You can replenish all of a few things. Therefore, the transfer operation for transferring the component boxes 2 and 3 to the manufacturing line 8 can be efficiently performed.

The kanbans 2a and 3a processed by the bar code reader 16 of the use input processing device 15 are sorted by factory by the sorting device 18 and handed to the driver of the truck 1 who delivers the parts every two hours.

Further, focusing on the parts box 3 that consumes quickly, the parts boxes 2 and 3 are automatically stored in the automatic warehouse 11 by balancing the timing when the parts box 3 does not become a dangerous stock and the timing when the truck 1 delivers. Can be transported to the parts shelves 9 of the manufacturing line 8 from the required number. As a result, there is no danger of a shortage of inventory in the parts box 2, and the Kanban 2 is well balanced with respect to the truck 1.
a, 3a can be handed over.

Further, the inventory management device 12 can easily manage the inventory of the component boxes 2 and 3 stored in the automatic warehouse 11 based on the kanbans 2a and 3a put into the kanban post 14.

This embodiment has been embodied in the case where all delivered parts boxes 2 and 3 are stored in the automatic warehouse 11. However, the number of parts in the parts boxes 2 and 3 is large, and one day (8 hours). It is not always necessary to store in the automated warehouse 11 up to the component boxes 2 and 3 which are empty during the period (between).

In the present invention, it is possible to store only large parts and small parts boxes 2 and 3 in which the number of parts to be stored in the parts boxes 2 and 3 is small in the automatic warehouse 11. That is, the component boxes 2 and 3 for storing large and medium-sized components become dozens of empty boxes per day. Further, although the number of delivered parts boxes 2 and 3 containing large and medium-sized parts is large, the number of parts to be put into the first and second storage shelves 10a and 10b is limited. for that reason,
Since the number of parts boxes 2 and 3 placed in the temporary storage area is large, the space must naturally be large.

However, if the present invention is adopted, the parts boxes 2 and 3 which require a space to be placed in the temporary storage space are stored in the automatic warehouse 11, so that the factory may have a small temporary storage space, and the parts can be stored in the automatic storage space 11. The storage management of the boxes 2 and 3 can be easily performed, and the transport efficiency can be improved.

In the present embodiment, the method of delivering the component boxes 2 and 3 containing the components has been embodied, but in some cases the components themselves may be placed on the pallet 4 and delivered. Also in this case, the above-mentioned payout method can be applied.

[0064]

As described in detail above, according to the present invention, there is an excellent effect that the parts stored in the automatic warehouse can be efficiently conveyed and supplied on the manufacturing line.

[Brief description of drawings]

FIG. 1 is a configuration diagram showing an inventory management system of a component box supplied to a manufacturing line.

FIG. 2 is a conventional configuration diagram showing a flow of a component box supplied to a manufacturing line.

FIG. 3 is a conventional configuration diagram showing a flow of a component box supplied to a manufacturing line.

[Explanation of symbols]

1 ... Trucks as transportation means 2a, 3a ... Kanban, 11 ... Automated warehouse

Claims (1)

[Claims] 1. A required part is delivered from an external factory on a production line every predetermined time by means of transportation,
After registering the type and number of parts based on Kanban showing various information of attached parts for each delivered part, this part is stored in the automated warehouse and removed every time the part is used on the manufacturing line. A method of paying out parts to be supplied to a production line, in which the number of parts that are stored in an automated warehouse is collected based on the number of collected Kanbans that are collected.