JPH08309647A - Method and device for production control - Google Patents

Abstract

PURPOSE: To provide a method and a device for production control for sufficiently answering requirement reducing an inventory amount. CONSTITUTION: A production instruction preparing portion 14 makes production instructions on a subproduct line in accordance with passage information of a work detected by a sensor A. When a work is detected by a sensor B, it is recognized whether works are fed in order with reference to an A-point passage information file 16. Unless the passage order is changed, a new production instruction is not made by a production process adjustment portion 30. If the order is changed, production of works on a subproduct line is to be operated in accordance with such a change. In the production instruction adjustment process portion 30, a new production instruction on the subproduct line is made in accordance with a product order on the main production line.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production control method and apparatus for producing a production plan for a sub production line according to the production status of a main production line.

[0002]

2. Description of the Related Art Conventionally, in a so-called mixed flow line, in which different kinds of works are produced on the same production line according to the status of an order, the purpose is to reduce the stock amount of assembly parts produced on a sub production line. Depending on the type of work put into the main production line, parts to be assembled to the work are produced in the sub-production line.

In such a production line, for example, in the main production line, A, B, C, D, A,
Work pieces of types A, B, B are input in this order,
When this production is performed, even in a sub-production line that produces parts to be assembled to these works, a, b, and
Parts of types c, d, a, a, b and b are put in this order.

What kind of work is produced in what order in the main production line is detected by a sensor provided on the upstream side of the main production line. It is a time when the production of the part that takes the longest production time among the types of parts produced on the sub-production line will be in time.

For example, in the case where the production is performed in the main production line in the above-described order, the production time of the type d of the component produced in the sub-production line is compared with that of other types of components. If it is the longest 50 minutes, the time to detect what kind of work is produced in what order in the main production line is at least 50 minutes of the completion time in the main production line. It must be before. If it is not detected at such a time, the completion time of the work on the main production line will be earlier than the completion time of the parts on the sub production line, and there will be a shortage of parts to be assembled into the completed work. This is because a situation will occur in which the main production line will be temporarily stopped.

[0006]

However, in such a conventional production method, the order of loading the parts to be produced in the sub-production line is simply determined according to the order of loading the workpieces produced in the main production line. Also, the timing of detecting in what order and what kind of work is being produced on the main production line is also the type of component that takes the longest production time among the parts produced on the sub-production line. Since it was decided according to the above, the type of parts with a shorter production time than this will be put in the finished product inventory for a long time, and as a result, a large amount of inventory will be put in the sub production line. Become. In addition to this, when a defect occurs during production on the main production line and a certain type of work is pulled out, the inventory of the sub production line is further increased.

This will be described in more detail with reference to FIG.

In the example of this figure, since the production time of the part of type a is the longest, the timing of detecting what kind of work has flowed in the main production line is the completion of the work in the main production line. It takes longer than the sum of the time required to complete this type of part a and the time required to respond to an unexpected situation in the sub-production line, that is, the safety stock time. The timing (point A in the figure) is set.

When such timing is set, parts b, c, d, e are also started to be produced at the same timing, so that the production is completed on the main production line. All parts produced on the sub-production line will be in stock. Furthermore, the production of these parts begins when the passage of the workpiece is detected by the sensor on the main production line,
If the work is extracted after this detection,
The change in the production sequence in the sub-production line cannot cope with the change in the production sequence in the main production line due to this sampling, resulting in an increase in the stock amount. This means that the original purpose of reducing inventory has not yet been fully achieved.

The present invention has been made in order to solve such a conventional problem, and an object thereof is to provide a production management apparatus capable of sufficiently responding to a request for reduction of the stock amount from the beginning. To do.

[0011]

The present invention for achieving the above object is constituted as follows in each claim.

According to the first aspect of the invention, there is provided a production control method applied to a production line for parallel production of a work to be assembled on the work on the sub-production line corresponding to the work produced on the main production line. , A work passing an upstream position of the main production line is detected, a work passing a midstream position of the main production line is detected, and a work passing through the upstream position and a work whose passage is detected at a midstream position are detected. When the passing order of the above is different, the production instruction of the sub production line is created in accordance with the passing order of the work on the main production line.

According to a second aspect of the present invention, there is provided a production control device for a production line, which parallelly produces a work to be assembled to the work on the sub-production line corresponding to the work produced on the main production line. Depending on the first sensor for detecting the passage of the work at the upstream position of the line, the second sensor for detecting the passage of the work at the middle position of the main production line, and the passage order of the works detected by the first sensor. Whether the sub-production line production instruction creating means for creating a production instruction in the sub-production line and the passage order of the works detected by the first sensor and the passage order of the works detected by the second sensor are the same. If it is determined that the passing order does not match with the determining means for determining the The production instruction created by the production line production instruction creator and having a new production instruction generating means for generating a correction to a new production instruction to match the path sequence.

[0014]

The present invention having the above-described structure operates as follows for each structure stored in each claim.

According to the first aspect of the present invention, when the passing order of the workpieces that have passed through the upstream position and the passing order of the workpieces that have been detected to pass through at the middle position are different, the sub production line is matched with the passing order of the workpieces in the main production line. Since the production instructions of the sub-production line are created, the work produced in the sub-production line can always match the production order of the work in the main production line, and even if the production sequence of the main production line is changed, the inventory of the sub-production line is changed. It becomes possible to suppress the increase in the amount.

According to the second aspect of the present invention, the determining means determines whether or not the work passing order detected by the first sensor and the work passing order detected by the second sensor are the same. The sub-production line production instruction creating means creates a production instruction in the sub-production line according to the passage order of the works detected by the first sensor. When the determining means determines that the passage order does not match, the new production instruction creating means corrects the production instruction created by the sub-production line production instruction creating means to match the passing order. Create a new production instruction.

Therefore, even if the production sequence of the main production line is changed, it is possible to suppress an increase in the stock quantity of the sub production line.

[0018]

An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is a block diagram showing a schematic configuration of a production management apparatus according to the present invention.

A sensor 10 which is a first sensor for detecting what kind of work has passed at a point A on the main production line, and a second sensor having a similar purpose at a point B on the same line. A sensor 12, which is a sensor, is provided.
The information detected by the sensor 10 is transferred to the A point passing information file 1 by the main line information reception processing unit 14.
6, and the information detected by the sensor 12 is stored in the B point passage information file 18 by the main line information reception processing unit 14. An example of the information stored in the A point passage information file 16 is shown in FIG.
As shown in, type of work (a, b, etc.), B point passage time, A point passage mark, work management NO
And so on. The information stored in the B point passage information file 18 is similar to this.

The subline lead time table 20 is
What kind of work is a table that stores how much time it takes for each process. Further, the main line lead time table 22 is a table in which the same information about the main line as that of the sub line is stored, and the details thereof are shown in FIG.

The production instruction creating section 24 functions as production instruction creating means and is based on the information stored in the A point passage information file 16, the subline lead time table 20, and the mainline lead time table 22. The production instructions of the main production line and the sub production line are created, and the production instructions are stored in the production instruction file 26.

Work type actual lead time file 28
Stores the passage time between the point A and the point B for each work, and in the instruction correction processing unit 30, the main line lead time table 22,
Based on the information stored in the production instruction file 26 and the work type actual lead time file 28, the production instruction stored in the production instruction file 26 is corrected and a new production instruction is output. When a new production instruction is created by the instruction correction processing unit 30, the production instruction stored in the production instruction file 26 is rewritten with this new production instruction. How the instruction correction processing unit 30 creates this production instruction will be described in detail later. In addition,
The instruction correction processing unit 30 functions as a judging means and a new production instruction creating means.

In the production control apparatus having the above-mentioned configuration, the following process is roughly performed to change the production order of parts on the sub-production line.

The production instruction producing section 14 produces an instruction to produce parts on the sub production line based on the passage information of the work detected by the sensor A. Next, when the work is detected by the sensor B, the work is flowing in order by referring to the A point passage information file 16 (whether the work is not extracted due to a defect between the points A and B). Etc.)

If the order of passage is not changed, the production of the parts on the sub-production line may be performed according to the original production instruction, so that the production process correction unit 30 does not create a new production instruction. On the other hand, if the order is changed, the parts must be produced on the sub-production line according to the change, so the production instruction correction processing unit 30
Then, new production instructions for the sub production line are created so as to match the production order on the main production line.

The outline of the processing is as described above, but more detailed processing will be described with reference to the flowcharts of FIGS. 4 and 5.

The main line information reception processing section 14 detects information from the sensors 10 and 12 (S).
1). When information is detected by the sensor A, this information is stored in the A point passage information file 16. The production instruction creating unit 24 creates a production instruction for the sub-production line according to the passage information of the A point passage information file 16 (S2, S3), and stores the time when the A point is passed in the A point passage information file 16. Store (S4). The production instruction creating unit 24 reads the time required for passing between A and B from the main line lead time table 22 and calculates the predicted passing time T1 of B point from the passing time of A point and this passing time, This is stored in the mainline lead time table 22 (S
5).

When information is detected by the sensor B,
This information is stored in the B point passage information file 18, and the production instruction creating unit 24 searches for the corresponding instruction data from the beginning of the information stored in the A point passage information file 16 and determines the passage order at the A point. It is determined whether or not and the order of passing at point B match. As an example of this determination, a B point passage mark as shown in FIG. 2 is attached every time the passage at the B point is confirmed, and the order change is determined depending on the presence or absence of this mark. (S6).

If the works are passed in order, the time required for the works to actually pass between AB is stored in the work type actual lead time file 28 (S7, S).
8) When the passage of the work at the point B is accumulated, the lead time values in the main line lead time table 22 (for example, the time to the process 3) are averaged based on the actual time detected so far. Calculate the value and replace with this average value. By performing the process of constantly replacing the average value in this way, it is possible to automatically correct a change in production time due to equipment modification or design change of the main production line, and it is possible to flexibly respond to the change ( S9, S10).

On the other hand, if the passing order of the workpieces is not in the order, the instruction correction processing unit 30 determines the time T2 between A and B from the passing time of the point A of the skipped workpiece and the current time.
Is calculated (S11). When this time T2 becomes larger than T1 + α, in other words, when the predicted passage time of the work becomes later than the margin time α, in the sub-production line of the part corresponding to this skipped work in the sub-production line. A process of changing the production order of parts in time series by adding only the input time α is stored in the production instruction file 26 as a new production instruction (S12, S).
13). Such processing is performed until the work is completed (S14).

The above processing will be described by showing a concrete example.

By the sensor 10, A, A, B, C, D,
If it is confirmed that the work has passed through B, D, A, ... In order to produce the parts on the sub-production line,
Types of parts corresponding to those works a, a, b, c,
The order is d, b, d, a, .... Sensor 12
If the passage of the work is detected in the order of A, A, B, C, D, D, A, ..., B to be produced between D and D is missing. A new production instruction of parts on the production line is given in the order of parts types a, a, b, c, d, d, a, ... Corresponding to those works. Since it is usual that the production time differs for each part, if the production order is determined by taking into account the production time, the parts are rearranged in chronological order according to the scheduled production time of each part. As a new production plan.

[0034]

As described above, according to the present invention, the following effects can be obtained for each claim.

According to the first aspect of the present invention, when the order of passing the workpieces which have passed through the upstream position and the order of passing the workpieces detected to pass through at the middle position are different, the sub order is set according to the order of passing the workpieces in the main production line. Since the production instruction of the production line is created, the work produced in the sub production line can be always matched with the production order of the work in the main production line, and even if the production sequence of the main production line is changed. It is possible to suppress an increase in the inventory quantity of the sub-production line. Claim 2
According to the above configuration, when the determining means determines that the passing order does not match, the production instruction created by the sub-production line production instruction creating means is corrected so as to match the passing order and a new one is created. Since a new production instruction is created, even if the production sequence of the main production line is changed, it is possible to suppress an increase in the inventory amount of the sub production line.

[Brief description of drawings]

FIG. 1 is a block diagram showing a schematic configuration of a production management apparatus according to the present invention.

FIG. 2 is a diagram showing an example of an A point passage information file shown in FIG.

FIG. 3 is a diagram showing an example of a mainline lead time table shown in FIG.

FIG. 4 is a flowchart showing a process of the production control device according to the present invention.

FIG. 5 is a flowchart showing a process of the production control device according to the present invention.

FIG. 6 is a diagram for explaining a conventional production method.

[Explanation of symbols]

 10, 12 ... Sensor, 14 ... Mainline information reception processing section, 16 ... A point passage information file, 18 ... B point passage information file, 20 ... Subline lead time table, 22 ... Mainline lead time table, 24 ... Production instruction Creation unit, 26 ... Production instruction file, 28 ... Work type actual lead time file, 30 ... Instruction correction processing unit.

Claims (2)

[Claims] 1. A production management method applied to a production line for parallel production of a work to be assembled to the work in a sub-production line corresponding to a work produced in the main production line, the position being upstream of the main production line. The work passing through the main production line is detected, and the work passing through the midstream position of the main production line is detected. A production management method characterized in that a production instruction for a sub-production line is created in accordance with a work passage order in a production line. 2. A production management device for a production line, which parallelly produces a work to be assembled to the work on a sub-production line corresponding to a work produced on the main production line, wherein the work is passed at a position upstream of the main production line. A first sensor (10) for detecting the passage of a workpiece, a second sensor (12) for detecting passage of a workpiece at a middle position of the main production line, and a passage order of workpieces detected by the first sensor (10). And (24) a sub-production line production instruction creating means for creating a production instruction in the sub-production line, a work passage order detected by the first sensor (10) and the second sensor (12). The judging means (30) for judging whether or not the passing order of the works is the same, and the judging means (30) determines the passing order. If it is determined that the new production instruction is not produced, the production instruction produced by the sub production line production instruction producing means (24) is corrected so as to match the passage order and a new production instruction is produced. A production instruction device comprising: a creating means (30).