JPH08206934A - Production progress degree control system - Google Patents

Abstract

PURPOSE: To control a production progress degree of a specific kind of part according to an actual production progress degree of a product main body by arranging an operation means to perform operation on a difference between an integrated value of a part manufacturing result integrating means and an integrated value of a product main body manufacturing result integrating means. CONSTITUTION: When a main body of a seat carried on an assembling line 1 is detected by a sensor 10, its detecting signal is inputted to an assembling result integrating part 18 of a respective progress degree difference display panel 11, and every time when the detecting signal is inputted, the ratio set by a ratio setting panel 12 is integrated in order as an assembling result of the main body of the seat. A foot switch 13 is stepped on one sewing line 7 side every time when sewing of a leather cover is completed by respective sewing lines, and its number of stepping times is integrated as a sewing result of the leather cover by a sewing result integrating part 19. Operation to find a difference between an integrated value of respective sewing results and an integrated value of assembling results is successively performed in a respective difference operation part 24. Its difference is displayed on a display window.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production progress management system in a product assembling process.

[0002]

2. Description of the Related Art The following is an example of an automobile seat assembly process. Here, an assembly line for assembling the sheet main body and sequentially transporting the sheet main body is provided, and the sheet is completed by sequentially supplying the covers to the assembling positions installed on the way and covering the sheet main body. In that case, two types of covers, a leather cover and a cloth cover, are prepared, and by selectively covering them, sheets with different specifications such as leather specifications and cloth specifications are produced in a predetermined order. For example, 1 lot 2
If you want to produce 0 seats, 15 will be leather specifications,
The other 5 are made of cloth. Then, when preparing the cover, for the reason of improving the production efficiency, only the leather cover is covered by the sewing line provided in the company, and the cloth cover is procured from an external cooperating factory.

In this case, since the number of seat bodies to be assembled on the assembly line is different from the number of leather covers to be manufactured on the sewing line, the production plan for the leather covers should be set separately from that for the seat bodies. Becomes Conventionally, the production plan for such leather covers is
It was set up by simply dividing the number to be manufactured in one day by the working hours.

[0004]

However, in the conventional leather cover production plan, the required number can be produced in terms of one day. However, looking at the production situation on the way, the actual production of the seat body is considered. It may not correspond to the progress. That is, if the production progress of the seat body is slowed or speeded up and fluctuates, the number of leather covers produced for the seat body may be excessive or insufficient. When the leather cover is produced in excess, it will be in stock, so not only will it be necessary to store it, but also extra work will be required for storage. On the other hand, if the production of the leather cover is not in time, the assembly line may have to be stopped.

The present invention was completed mainly based on the above-mentioned circumstances, and by assembling one of plural kinds of parts to an unfinished product main body, finished products with different specifications are sequentially manufactured. Provided is a system capable of managing the production progress of a specific type of component in accordance with that of the product body when the assembly line for manufacturing the component and the component production line for producing only the specific type of component are owned. The purpose is to

[0006]

[Means for Solving the Problems] As means for achieving the above object, the present invention sequentially conveys common unfinished product bodies, and a plurality of types of product bodies are provided at predetermined assembly positions. It has an assembly line for sequentially manufacturing finished products having different specifications by selecting and assembling one of certain parts, and parts except a specific kind of the plural kinds of parts are supplied from the outside. On the other hand, for specific types of parts, they should be sequentially produced on a parts production line installed at another location, and the production progress of the specific types of parts should be adjusted to the production progress of the unfinished product body. A system for managing, a ratio setting means for presetting a ratio of the number of parts of the specific type required for a certain number of unfinished product bodies, and the ratio setting device before the assembling position. Detecting means for sequentially detecting unfinished product bodies conveyed on the vertical line, and each time the unfinished product body is detected by the detecting means, the ratio set by the ratio setting means is set to the product body. A product main body production record accumulating means for sequentially accumulating as a production record of the product, and a component manufacturing record accumulating means for sequentially accumulating the number as a part production record every time the specific type of part is produced in the part production line. , The integrated value of the part manufacturing record integrating means,
The present invention is characterized in that it is provided with a computing means for computing the difference between the integrated values of the product body manufacturing record integrating means, and a display means for performing various displays based on the results of the computation by the computing means. The block diagram of the present invention is shown in FIG.

[0007]

The operation of the present invention is as follows. First, the ratio setting means presets the ratio of the number of specific types of parts required for a fixed number of unfinished product bodies.
When the unfinished product main body is sequentially conveyed on the assembly line and reaches a predetermined detection position, the detection means detects each time. Every time the detection means detects the product body, the above-mentioned ratio is sequentially added as the production result of the product body by the product body production result accumulating means. On the other hand, every time a specific type of part is produced on the part production line, the number of parts is added as the part manufacturing result by the part manufacturing result accumulating means. Then, the calculation means calculates the difference between the integrated value obtained by the component manufacturing record integrating means and the integrated value obtained by the product body manufacturing record integrating means, and based on the calculation result,
Various displays relating to the status of production progress of the specific part are displayed by the display means.

[0008]

According to the present invention, the production progress of a specific type of component can be managed according to the actual production progress of the product main body, and the specific type of component is excessive or insufficient depending on the product main body. It is possible to produce without. As a result, there is no risk of holding a certain type of parts in inventory, it is not necessary to provide a storage place for them, and it is not necessary to carry out extra storage work. There is an effect that it can be avoided and the finished product can be efficiently manufactured as a whole.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which the present invention is applied to a process for assembling a vehicle seat will be described below with reference to the accompanying drawings. <First Embodiment> FIGS. 2 to 5 show a first embodiment of the present invention. In FIG. 2, reference numeral 1 denotes a seat assembly line, which is composed of four assembly lines 1a to 1d corresponding to front seat cushion, front back, rear seat cushion and rear back parts. In each of the assembly lines 1a to 1d, the main body of the front seat cushion, the front back, the rear seat cushion, and the rear back is assembled and intermittently conveyed in synchronization with the arrow direction, and the cover is installed at a predetermined position. It is supposed to be sent to 2 in sequence.

Assembling of the covers is carried out, for example, for 20 units each as one lot. The assembled cover is prepared separately for each part of a front seat cushion, a front back, a rear seat cushion and a rear back. Along with this, two types of covers, a leather cover and a cloth cover, are provided, and for example, 15 of the 20 cars are leather covers and the remaining 5 cars are cloth covers. In this embodiment, the leather cover is manufactured in parallel with the assembly line 1 by the sewing line 7 described later, and the cloth cover is manufactured in an external cooperating factory and sequentially carried in.

The covers for these 20 units are sequentially stacked for each part on the shelf 4 of the cover standing cart 3 as shown in FIG. 4 based on the production instruction sheet 5, and the corresponding assembling positions. It is carried in to 2. Then, at each assembling position 2, the cover is taken out from the standing cart 3 in order, and the assembly line 1
The work of sequentially covering the conveyed main body is performed.
Each seat covered with the cover undergoes an inspection process (not shown), and then the front seat cushion and the front back are assembled together, and the rear seat cushion and the rear back are assembled together, and they are further assembled into one set. Thereby, the leather specification sheet and the cloth specification sheet are manufactured and carried out in a predetermined order.

The above sewing line 7 for the leather cover is provided at a place different from the assembly line 1, and the assembly line 1
It is composed of four sewing lines 7a to 7d similarly to. In each of the sewing lines 7a to 7d, a leather cover corresponding to each part of the front seat cushion, the front back, the rear seat cushion and the rear back is sewn. In this sewing line 7, the next lot of sheets to be assembled in the assembly line 1 is sewn in advance. The sewn leather covers are sequentially placed on the shelves 4 of the cover standing cart 3 as described above based on the production instruction sheet 5 for the next lot. In that case, for example, only 15 cars can be placed on the shelf 4, and the rest remain empty. After the sewing of the leather cover and the loading of the cart 3 in the lot are completed, the cloth cover brought in from the outside cooperating factory is placed on the empty shelf 4. And
Each trolley 3 loaded with a cover for 20 vehicles is carried into the assembly position 2 of the corresponding assembly line 1a to 1d, and when the previous trolley 3 is emptied, it is replaced with that trolley 3 and subsequently. The cover of the next lot is assembled.

Next, the structure of the production progress management system will be described. On one side of the assembly line 1 such as the rear back assembly line 1d, a detection position 9 where a sensor 10 is installed is provided on the front side of the cover assembly position 2, and the assembly line 1d is intermittently provided. A detection signal is sent from the sensor 10 every time the main body of the rear bag that has been conveyed is stopped at the detection position 9. Since the bodies of the parts of the same sheet are conveyed in synchronization with each other, it is considered that all the parts have been conveyed only by detecting the body of the rear back.

On one sewing line 7 side, a progress difference display board 11 is installed at the end of each sewing line 7a to 7d. The above-mentioned sensor 10 is connected to the input side of each progress difference display panel 11, and also each ratio setting panel 12 and each foot switch 13 are connected. Also, different warning lights 14 are connected to the output side.

The ratio setting board 12 is for setting the ratio of the required number of leather covers to the number of seats of one lot, and 20 leather covers of one lot require 15 leather covers. If there is one, the required number of leather covers is "1" from the input section.
When 5 "is input, 15/20 = 0.75 is calculated and" 0.75 "is set as the" ratio ". The input numerical value is confirmed by the display window 16 as shown in FIG. The set "ratio" is one unit in the case of integrating the assembly results of the seat body, which will be described later.

As shown in FIG. 3, each progress difference display panel 11 is provided with an assembly record accumulating section 18 and a sewing record accumulating section 19, respectively. The assembling result accumulating unit 18 is for accumulating the assembling results of the main body of the seat, so that each time the detection signal is received from the sensor 10, the above-mentioned "ratio", that is, the numerical value "0.75" is sequentially added. Has become. The integrated value R is displayed on the display window 21 as shown in FIG.

The sewing result accumulating section 19 is for accumulating the sewing results of the leather cover, and by depressing the foot switch 13 every time the cover sewing is completed, the number of covers sewn is sequentially calculated. It is supposed to be done.
The integrated value r is displayed on the display window 22.

Further, each progress difference display panel 11 has a difference calculator 2
4 are provided. The difference calculation unit 24 calculates the difference D when the integrated value R of the assembly result integration unit 18 is subtracted from the integrated value r of the sewing result integration unit 19, that is, "D = r.
The operation "-R" is performed. The difference D is displayed on the display window 25.

Further, each progress difference display panel 11 is provided with a lighting control unit 27 for controlling lighting of the warning lamp 14 based on the difference D calculated by the difference calculation unit 24. As shown in FIG. 5, the warning light 14 includes a green light portion 14a and a yellow light portion 1
4b and a red light unit 14c are provided. Then, the lighting control unit 27 determines that the numerical value of the difference D is “D ≧
If it is "-0.1", the green light unit 14a is turned on, and "-0.
If 1> D ≧ −1 ”, the yellow light unit 14b is turned on, and if“ D <−1 ”, the red light unit 14c is turned on.

The present embodiment has the above-mentioned structure, and its operation will be described below. First, when the number of leather covers required for one lot, for example, "15" is input to the ratio setting panel 12, 15/20 = 0.75 is calculated and "0.75" is calculated.
Is set as the "ratio".

When the body of the sheet conveyed on the assembly line 1 is detected by the sensor 10, the detection signal is input to the assembly record accumulating unit 18 of each progress difference display panel 11, and each time the detection signal is input. The ratio "0.75" set on the ratio setting board 12 is sequentially added up as the actual assembly result of the seat body. The integrated value R is displayed in the display window 21 as “0.7
5 "," 1.5 "..." 0.75N "are sequentially displayed, where N is the number of detections.

On one sewing line 7 side, the foot switch 13 is stepped on each time the sewing of the leather cover is completed on each of the sewing lines 7a to 7d, and the stepping frequency n is the sewing result of the leather cover and the sewing result is integrated. It is accumulated in the part 19. The integrated value r of "1", "2" ... "N" is sequentially displayed in the display window 22. Then, in each difference calculation unit 24, a calculation “D = r−R” for obtaining a difference D between the integrated value r of the sewing results and the integrated value R of the assembly result is sequentially performed. The difference D is displayed on the display window 25.

Here, for example, if 10 sheet bodies are detected in the assembly line 1, the integrated value R of the assembly results is R = 0.75 × 10 = 7.5, and sewing is performed in the meantime. If the number of completed leather covers is eight, the integrated value r of the actual sewing results is r = 8, and the difference calculation unit 24
The calculation of "D = r-R = 8-7.5" is performed, and the difference D =
A calculation result of +0.5 is obtained.

This difference D = + 0.5 indicates that the production progress of sewing is ahead of the production progress of assembly, and corresponds to "D ≧ -0.1" of the lighting condition of the warning light 14. Therefore, receiving the control signal from the lighting control unit 27, the green light unit 14
a is turned on. This confirms that the sewing work is proceeding smoothly. If it is confirmed through the display window 25 that the + value of the difference D is considerably large, it means that the progress of the sewing production is too advanced, so that the pace of the sewing work is reduced.

If seven leather covers are sewn by the time the ten seat bodies are manufactured, the difference calculation unit 24 calculates "D = 7-7.5". Thus, the calculation result of the difference D = −0.5 is obtained. This difference D = −0.
5 indicates that the production progress of sewing is slightly behind, and the yellow light portion 14b is turned on because the lighting condition of the warning light 14 corresponds to "-0.1> D ≧ -1". This urges the sew maker to rush work.

Further, if only six leather covers are sewn by the time the ten seat bodies are manufactured, the difference calculator 24 calculates "D = 6-7.5". Is performed, and the calculation result of the difference D = −1.5 is obtained.
This difference D = -1.5 indicates that the production progress of sewing is significantly delayed, and the lighting condition of the warning light 14 is "D <-1".
Therefore, the red light unit 14c is turned on. As a result, a significant increase in pace is promoted for the corresponding sewing lines 7a to 7d by, for example, supporting the sewing manufacturer.

In this way, the production of the leather cover of each part is performed by raising or lowering the sewing pace of the sewing lines 7a to 7d according to the display of the warning lights 14 arranged on the sewing lines 7a to 7d. It is possible to match the progress with the production progress of the main body of the seat.

When the detection of the main bodies of the sheets for one lot is completed, the progress difference display panel 11 is reset and the above operation is repeated. At that time, if the required number of leather covers in the next lot changes, the ratio setting panel 12
The input value to can be changed accordingly.

As described above, by using the management system of this embodiment, the production rate of the leather cover can be controlled according to the actual production rate of the seat body, and the leather cover can be attached to the body of the seat. Correspondingly, it becomes possible to produce without excess and deficiency. As a result, there is no risk of holding the leather cover in stock, it is not necessary to provide a storage place for it or to perform extra storage work, and the assembly line must be stopped because the leather cover cannot be produced in time. It is possible to avoid the situation that does not happen, and it is possible to efficiently manufacture the seat as a whole.

<Second Embodiment> FIG. 6 shows a second embodiment of the present invention in which the control system of the management system is modified. In the above-described first embodiment, each sewing line 7a-7
In each of the advancement difference display panels 11 provided at the end of d, input / output control and various calculations are performed respectively, but in the second embodiment, these input / output control and various calculations are common. The control panel 30 is used. On the other hand, in the progress difference display panel 11a of the second embodiment, a display window 21 for displaying an integrated value R of assembly results, a display window 22 for displaying an integrated value r of sewing results, and a display window for displaying a difference D thereof. 25 is provided and only the display function is performed.

That is, the sensor 10 provided on the assembly line 1 is connected to the input side of the control panel 30, and the same four as the four ratio setting panels 12 provided on the sewing lines 7a to 7d. Foot switch 13 is connected. Also, on the output side, each sewing line 7a is also the same.
Four advancement difference display boards 11a and four warning lights 14 provided at 7d are connected to each other.

Then, in the control panel 30, the assembling results are accumulated for each of the sewing lines 7a to 7d based on the detection signal from the sensor 10 and the "ratio" set in each proportional setting panel 12. The sewing results are integrated based on the input signal from each foot switch 13, and the difference between them is calculated. The result of the calculation is each sewing line 7a.
It is displayed on each of the progress display boards 11a provided at 7d and the lighting of each warning lamp 14 is controlled in accordance with the difference calculation result. The effect is similar to that of the first embodiment described above.

<Other Embodiments> The present invention is not limited to the embodiments described above and illustrated in the drawings. For example, the following embodiments are also included in the technical scope of the present invention. In addition to the above, various modifications can be made without departing from the scope of the invention.

(1) Numerical values such as the number of seats in one lot and the number of leather covers required for one lot shown in the above embodiment are merely examples, and the present invention is not limited to such numerical values. Needless to say. (2) In addition, a warning buzzer may be added to the warning light.

(3) Further, the present invention is not limited to the automobile seat assembling process shown in the above embodiment, but is one of a plurality of types of parts for an unfinished product body such as an assembling process of other home electric appliances. If you have an assembly line that sequentially manufactures finished products with different specifications by assembling, and a parts production line that produces only specific types of parts, match the production progress of the specific types of parts with that of the product body. It can be applied to all cases.

[Brief description of drawings]

FIG. 1 is a block diagram showing a configuration of the present invention.

FIG. 2 is a schematic configuration diagram of a first embodiment of the present invention.

FIG. 3 is a block diagram thereof.

FIG. 4 is a perspective view of a cover standing cart.

FIG. 5 is an enlarged configuration diagram near the progress difference display panel.

FIG. 6 is a block diagram of a second embodiment.

[Explanation of symbols]

 1 ... Assembly line 2 ... Cover assembly position 7 ... Sewing line 9 ... Detection position 10 ... Sensor 11 ... Progress difference display panel 12 ... Ratio setting panel 13 ... Foot switch 14 ... Warning light 18 ... Accumulation unit 24 ... Difference calculation unit 25 ... Display window 27 ... Lighting control unit 11a ... Progress difference display panel 30 ... Control panel

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Masahiro Akasaku No. 2 of 109 Tanada, Wakabayashi Higashi-cho, Toyota-shi, Aichi Ono Electric Co., Ltd.

Claims (1)

[Claims] 1. A common unfinished product body is sequentially transported, and one of a plurality of types of each product body is selected and assembled at a predetermined assembly position to sequentially produce finished products having different specifications. There is an assembly line for manufacturing, and parts of the above-mentioned plurality of types except for those of a specific type are supplied from the outside, while parts of a specific type are provided in a separate part production line. A system for sequentially producing and controlling the production progress of the specific type of parts so as to match the production progress of the unfinished product body. Ratio setting means for presetting the ratio of the number of the specific type of parts required, and detection for sequentially detecting unfinished product bodies conveyed on the assembly line before the assembly position. And stage, each time the unfinished product body at the detection means is detected,
A product body manufacturing record accumulating means for sequentially accumulating the ratio set by the ratio setting means as a manufacturing record of a product body, and the number of parts each time the specific type of parts is produced in the parts production line. A component manufacturing record accumulating means for sequentially accumulating as a manufacturing record, a calculating means for calculating a difference between the integrated value of the component manufacturing record accumulating means and the integrated value of the product body manufacturing record accumulating means, and a calculation result of the calculating means A production progress management system, comprising: a display unit for performing various displays based on the above.