JPH10212008A - Empty pallet number transition predicting device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an empty pallet number transition predicting device that can correctly predict and display the decrease transition of the number of empty pallets in a goods in process warehouse. SOLUTION: This predicting device computes the number of pallets accepted from forming machines, the number of pallets delivered to an after-process, and the number of after-process applied product pallets and the number of after-process unapplied product pallets out of the accepted pallets for each forming machines every specified time from the present time on the basis of goods in process warehouse shelf stock data, delivery planning data, after- process working capacity master data, after-process working time master data, and forming planning data and present production quantity data of the forming machines taken in from forming control computers 11, 12. The predicting device then displays a graph of the increase/decrease number of empty pallets in a goods in process warehouse, and a chart of the number of accepted pallets for each of their packed products and nonpacked products for every forming machine.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for predicting a change in the number of available empty pallets in a work-in-process warehouse in a transport equipment management system.

[0002]

2. Description of the Related Art As shown in FIG. 1, an empty pallet is transported from a work-in-progress warehouse to a molding facility, where the work-in-progress produced by the molding facility is loaded, and then is stored in the work-in-process warehouse.
The work-in-progress loading pallet in the warehouse is conveyed to a post-processing line, where the work-in-progress is taken out and entered into the work-in-process warehouse as an empty pallet. A technique relating to the handling of the pallets when carrying out such transportation and storage is disclosed, for example, in JP-A-59-57802.

By the way, the loading of the pallet loaded with the work in process from the molding equipment and the supply of the empty pallet to the molding equipment are as follows.
It is performed continuously for 24 hours during the operation of the molding machine. On the other hand, in the transport equipment, generally, the post-process unloading from the work-in-process warehouse is performed only in the daytime (for example, from 9:00 am), and the unloading of empty pallets based on the molding plan is not performed in the nighttime.

Conventionally, therefore, as shown in the work flow of FIG. 2, an operator first checks the current number of empty pallets by looking at the display contents (for example, Table A in FIG. 3) of the transport management computer. Based on the data on the number of empty pallets, the data on the current production volume of the molding machine, and the data on the number of pallets to be delivered per unit time (forecast) based on the experience of the operator, at 9 am the next morning, The available empty pallets at the time when the unloading operation of the pallets loaded with work in process to the post-processing equipment is executed are roughly calculated by hand, and based on the calculation result, whether the empty pallets run short at 9 am the next morning We are working to predict whether or not.

[0005] In such a prediction, the next morning, 9
If there is not enough empty pallets at the time, a process of manually carrying out the pallets already loaded with the work-in-progress is performed first (open the pallets in large numbers).

[0006]

In the above-described conventional processing method, the calculation result (the estimated number of empty pallets) is
When the consumption of empty pallets is large (when the production volume is higher than expected) and the result of the shortage of empty pallets at 9 am the next morning, it is difficult to know when the shortage of empty pallets will start and the accuracy is poor. is there.

In this type of transport management system, the molding machine operates continuously for 24 hours as described above.
It is necessary to always ensure that empty pallets to be supplied to the molding machine are sufficient, but it is difficult to determine whether or not empty pallets are in short supply by the conventional method, and when they are in short supply, when the shortage will occur.

For this reason, in some cases, as shown in the work flow of FIG. 2, a pallet on which a work-in-progress is mounted is previously carried out from a work-in-process warehouse, and a part of the work-in-progress is transferred to another warehouse. It is necessary to carry out work such as securing empty pallets, but it is difficult to schedule work because it is not known when such emergency dispatch work should be carried out.・ This was a cause of inefficiency in arrangement and daily work.

Further, if an empty pallet is insufficient and emergency carrying-out work cannot be performed in time, in the worst case, there is a possibility that the molding equipment must be stopped. The present invention has been made in view of such a situation, and an object of the present invention is to provide an empty pallet number transition prediction device capable of accurately predicting and displaying a decrease transition of the number of empty pallets in a WIP warehouse.

[0010]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention relates to a process of loading a work-in-process pallet from a molding facility to a work-in-process warehouse, supplying an empty pallet to the molding facility, and a work-in-progress based on a delivery plan. In the transport equipment management system that manages the unloading of pallets loaded with WIP from the warehouse to the post-processing equipment and the loading of empty pallets that have been processed from the post-processing to the WIP warehouse, the available empty space in the WIP warehouse A device for predicting the change in the number of pallets, which is a work in progress warehouse shelf inventory data, a delivery plan data, a post-process work capacity master data, a post-process work time master data, and molding plan data taken from a molding management computer and Based on the current production amount data of the molding machine, the number of pallets to be taken in from the molding machine, the number of pallets to be taken out to the post-process, And a calculation unit that calculates the number of post-process pallets for incoming pallets for each molding machine and the number of unused pallets for post-process, and calculates the number of empty pallets in the WIP warehouse based on the calculation results. It is characterized by having a display unit for displaying.

Here, the work-in-process warehouse shelf inventory data used in the present invention is data on the presence / absence of pallets in all storage spaces in the current work-in-process warehouse and detailed information on the pallets, and the delivery planning data is delivered to a subsequent process. Information on individual pallets of products, number of pallets and data on order.

The post-process work capability master data is as follows:
Post-process work time master data is data related to the scheduled work time of one day.

Further, the molding plan data is data taken from a molding management computer, and includes a production order of each molding machine.
It consists of information such as the production number, the number of productions, and the actual production volume per hour, and uses the actual production data per production number / time.

According to the present invention having the above-described structure, the present state of the empty pallet can be easily and accurately grasped by the display information on the display unit, so that the operator can periodically check at an appropriate time. By doing so, the occurrence of the problem (insufficient empty pallet) can be predicted in advance.

Further, in the present invention, it is also possible to separately calculate the unpackaged product and the unpackaged product which can be subjected to the emergency delivery work preferentially, by separately calculating the required product and the unpackaged product. .

Here, in the present invention, in addition to the above-described configuration, the number of empty pallets in the work-in-process warehouse obtained by the calculation in the operation unit is monitored, and the number of empty pallets becomes equal to or less than a preset number. At times, a function of generating an alarm may be added.

When such a configuration is adopted, an alarm is automatically generated before the shortage of empty pallets occurs, so that a periodic check is not required and labor can be saved. Further, since the worker can leave the work related to the empty pallet management until the alarm is generated, other work can be performed during that time. There is also an effect that it is possible to prevent forgetting to check.

The quantity to be set in the configuration for generating an alarm is not particularly limited and is arbitrary, and may be any size, such as the size of the warehouse, the work period for each type of work in process, and the number of spare pallets (for example, 20% of the total number of operating pallets). Etc.) may be appropriately set for each target factory.

[0019]

Embodiments of the present invention will be described below with reference to the drawings. First, a system to which the present invention is applied will be described with reference to FIG.

The example shown in FIG. 4 is a transport equipment management system in an extrusion molding factory, which comprises a molding equipment, a transport equipment, and an inspection packing equipment. The molding equipment is provided with molding management computers 11, 12,... For individually managing each molding machine. In addition, the transport equipment
A transfer control computer 21 for controlling the driving of the crane control controller 22 and the like is arranged, and these forming management computers 11, 12,... And the transfer control computer 21 are connected to the transfer management computer 1 via communication lines. .

The transfer management computer 1 supplies an in / out instruction signal to the transfer equipment computer 21 in accordance with molding plan data and operation information from each of the molding management computers 11, 12,... It manages the flow, and as shown in FIG. 5, includes an arithmetic processing unit 1a, a data storage unit 1b, a display / setting unit 1c, a communication data conversion processing unit 1d, and an external communication interface unit 1e.

The arithmetic processing section 1a of the transfer management computer 1 performs not only the above-mentioned transfer control such as the above-mentioned in-and-out instructions, but also the in-process warehouse shelf stock data, the outgoing plan data, and the inspection stored in the data storage section 1b. The number of pallets to be received from the molding machine every 10 minutes from the current time based on the packing work master data, the inspection packing work time master data, and the molding plan data and molding machine current production data taken from the molding management computer. With the function to calculate the number of pallets to be delivered to the inspection and packing process, and the number of pallets required for packing of incoming pallets and the number of pallets of non-packed products by molding machine by the method as exemplified below. I have.

The calculation result is output to a display device 2 (FIG. 4) such as a CRT via a display setting section 1c, and is displayed on a screen of the display device 2 in a work-in-process warehouse as illustrated in FIG. Is displayed, and a list of the number of incoming pallets of the packing product “packing” and the unpacking product “naked out” for each molding machine is displayed.

Here, the data used for calculating the empty pallet in this example are as follows. Outgoing planning data; Presence / absence of pallets in all storage spaces in the current WIP warehouse, detailed information on pallets Inspection and packing work capacity; Product information of pallets to be delivered to the inspection packing area (post-process) Inspection / packing work time; Scheduled work time per day Master data Molding plan data: Data taken from the molding management computer, consisting of information such as the production order, production part number, number of production, and actual production volume per hour of each molding machine Use the actual production data per production part number and time [Basic calculation example] ・ Amount of empty pallet used Molding machine 1: Part number A Current production amount 150Kg / h Pallet capacity 600Kg Pallet is full Time = 600/150 = 4 hours The pallet becomes full every 4 hours.

Similar calculations are performed for all molding machines.・ Amount of empty pallets to increase Delivery schedule 1. Part number A 10 pallet Part number A processing time 5 minutes Work start time 9:00 2. Part number B 5 pallet Part number B processing time 6 minutes 3. Part number C 10 pallets Part number C processing time 4 Minutes Calculation content One pallet is delivered every 5 minutes from 9:00, and 10 empty pallets are added (required time: 50 minutes) Part number A 9:50 End One pallet is delivered every 6 minutes from 9:50 The number of empty pallets increases by 5 pallets (required time: 30 minutes) The time is shifted for a break of 10 minutes from 10 o'clock (+15 minutes) ... Part number B10: 35 end One pallet is delivered every 4 minutes from 10:35 , Empty pallets increase by 10 pallets (required time: 40 minutes) ・ ・ ・ ・ Part number C11: 15 End After calculating all the sunrise plans by the same method, the number of pallets increased / decreased every 10 minutes from the current time is counted. Create a graph.

In this example, a graph of the increase / decrease number of empty pallets in the work-in-process warehouse obtained by the above calculation process and a list of the number of incoming pallets for each packaged / unpackaged product are displayed (FIG. 6), and the worker checks FIG.
As shown in the work flow, the number of empty pallets at the present time is checked, and the decrease in the number of empty pallets in the WIP warehouse is confirmed. If left untouched, perform daily tasks.

On the other hand, if it is found from the display screen that "empty pallet is out" by 9:00 the next morning, the time at which the pallet has run out is confirmed, and a manual unloading operation of the pallet loaded with the work-in-progress is incorporated into today's work process. Perform daily tasks after scheduling work.

Here, the above confirmation work can be arbitrarily performed at any time, so that if it is carried out regularly, even when the production volume changes, it is possible to easily cope with the change. As a result, emergency dispatch work becomes unnecessary.

In addition, in addition to the configuration of the above embodiment,
A function to monitor the number of empty pallets in the WIP warehouse obtained by calculation and to generate an alarm when the number of empty pallets becomes equal to or less than a preset number may be added. When employed, an alarm is automatically generated before the shortage of empty pallets occurs, so that periodic checks are not required and labor can be saved. Further, since the worker can leave the work related to the empty pallet management until the alarm is generated, other work can be performed in the meantime. There is also an effect that it is possible to prevent forgetting to check.

[0030]

As described above, according to the present invention,
WIP warehouse shelf inventory data, delivery planning data, post-process work capacity master data, post-process work time master data,
In addition, based on the molding plan data and the current production amount data taken from the molding management computer, the number of pallets to be received from the molding machine, the number of pallets to be delivered to the post-process, and the storage for each molding machine at predetermined time intervals from the current time The number of pallets used in post-process pallets and the number of pallets not used in post-process are calculated, and the number of empty pallets in the WIP warehouse is configured to be displayed. ,
A decrease in the number of empty pallets in the WIP warehouse can be predicted in advance. This allows for accurate arrangement of workers
A work schedule can be set for the day, and work can be performed efficiently. In addition, since the occurrence time of the empty pallet shortage can be accurately predicted, it is not necessary to perform an emergency retrieval operation.

[Brief description of the drawings]

FIG. 1 is a diagram showing a flow of a product pallet.

FIG. 2 shows an example of a conventional work flow.

FIG. 3 is a diagram showing a conventional display example of a pallet number display screen in a WIP warehouse.

FIG. 4 is a diagram showing a configuration of a transport equipment management system to which the present invention is applied;

FIG. 5 is a block diagram showing a configuration of a transport management computer used in the embodiment of the present invention.

FIG. 6 is a diagram showing a display example of an empty pallet number transition prediction screen obtained in the embodiment of the present invention.

FIG. 7 is a diagram showing an example of a work flow using display information on the empty pallet number transition prediction screen.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Conveyance management computer 1a Arithmetic processing part 1b Data storage part 1c Display setting part 1d Communication data conversion processing part 1e External communication interface part 2 Display device 11, 12 ... Molding management computer 21 Transport control computer

Claims (2)

[Claims] Claims: 1. An in-process loading pallet is transferred from a molding facility to a work-in-process warehouse, an empty pallet is supplied to the forming facility, an in-process loading pallet is discharged from the in-process warehouse to a post-process facility based on a delivery plan, and A device for predicting a change in the number of empty pallets that can be used in a WIP warehouse in a transport equipment management system that manages the operation of loading a processed empty pallet into a WIP warehouse from a subsequent process. Inventory data, delivery plan data, post-process work capacity master data, post-process work time master data,
Also, based on the molding plan data and the current production amount data of the molding machine taken from the molding management computer, every predetermined time from the current time, the number of pallets to be received from the molding machine, the number of pallets to be delivered to the subsequent process, and Calculating unit for calculating the number of pallets used in the post-process and the number of pallets not used in the post-process for incoming pallets by molding machine, and displays the number of empty pallets in the WIP warehouse based on the calculation results An empty pallet number transition prediction device, comprising: 2. A means for monitoring the number of empty pallets in the work-in-progress warehouse obtained by the above calculation and generating an alarm when the number of empty pallets becomes equal to or less than a preset amount is provided. The empty pallet number transition prediction device according to claim 1, wherein: