JPS6020844A - Machining/assembly mutual load smoothing production method - Google Patents

Abstract

PURPOSE:To reduce devices required between the processes of machining and assembly and unify product stocks by allowing groups per each product machining pass process to appear at a uniform interval for smoothing the machining process and allowing groups per each type to appear at a uniform interval within this limitation for smoothing the load of assembly job. CONSTITUTION:Group categories used for the machining pass process in the substrate assembly schedule plan are obtained by summing the number of requested rots in category of groups, e.g., 6 rots for A group and 6 rots for B group. These categories are fed at a uniform interval to smooth the load of the machining process. In this case, the sequence becomes ABAB.... Furthermore, each type in each group is arranged at a uniform interval to unify the stocks of each type. Thereby, a production plan can be established to smooth the requested production quantity and the machining/assembly job and to unify the stocks of each type. The assembly work sequence to maintain the job smoothing is directed based on the production results, and uncompleted products are urged by means of a visual synchronization control panel 8 based on the direction of the machining feed sequence in synchronization with the assembly progress and the momentary production results.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Application of the Invention] The present invention relates to a processing/assembly mutual load leveling production system suitable for producing a wide variety of products.

[Background of the invention]

The conventional multi-product production system, for example, focuses on equalizing product inventory and leveling the load of assembly work, and plans production plans for the assembly line, and then manages the progress of assembly and processing based on this. As a result, load imbalance occurs during the machining process, making it extremely difficult to synchronize parts between machining and assembly, and creating unnecessary mechanisms during machining and assembly.

[Purpose of the invention]

The purpose of the present invention is to eliminate the above-mentioned drawbacks of the prior art, establish a production plan that equalizes product inventory and simultaneous leveling of processing and assembly operations, and connects processing and assembly with a minimum of mechanisms. The objective is to provide a production system that can level out the mutual loads of processing and assembly.

[Summary of the invention]

The configuration of the processing/assembly mutual load leveling production system according to the present invention is based on a basic assembly schedule plan for products of various types that are mixedly produced, each product is grouped by passing processing process, and each group is divided at equal intervals. In addition, there is an assembly work order planning process that calculates so that each product type is equally spaced within each group, and a processing work order plan process that calculates that the machining work is leveled for each processing process based on this. and a line progress management process that outputs synchronized management data based on the result of the assembly work sequence planning process, and an assembly line work plan created from the assembly work sequence planning process, and the same processing work sequence plan. The production process is operated based on the work plan for the processing line created from the processing.

In short, in order to level out processing and assembly operations at the same time, products are grouped by processing process.

By making this group appear at equal intervals.

First, by leveling the machining process and making products appear at equal intervals within this constraint, the aim is to level out the assembly work load and equalize the product inventory.

In addition, FIG. 1 shows a schematic diagram comparing the conventional method and the present method in the case where only one type of product is focused and the case where processing passing steps are taken into account.

In this example, one variety α1. α2. a3. There are 5 scales, bl and b2, and the passing processing process for one type α, ~a3 is S, process.

The A20 passing processing process is the S2 process, and the required lot for each type is 20 pieces or 60 pieces, and the case where the daily production on the assembly line is 20 pieces is shown.

In the conventional method of equal spacing by product type, the amount of processing work is unbalanced on a daily basis, whereas in the case of this method, which aims to create equal spacing by group and by product type, the amount of processing work is unbalanced on a daily basis. Leveled.

[Embodiments of the invention]

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

FIG. 2 is an explanatory diagram of the structure of an embodiment of the production system for equalizing the processing and assembly loads according to the present invention.

Here, 1 is a processing device (for example, a computer).

2 is the output work plan for the assembly line, 3 is the work plan for the recirculating line, and the above plans 2 and 3 are, for example, work instructions that are output in patches on a daily basis. 4-1, 4-2, 4-3 are processing lines, 5 is 1 assembly line, 6-1゜6-2.6-5 is processed finished product, 7 is 1 assembled finished product (product), 8 1 is a visual synchronization management board for displaying synchronization management data as a result of the line progress processing of the processing device 1, for example, real-time work order display on the assembly line 5 and processing line 4.
It shows the degree of gathering of processed finished products (before the assembly line) based on the work results from -1 to 4-3.

The processing contents of the processing device 1 are shown below.

(1) Assembly basic schedule planning Creation of an assembly schedule plan that aims to achieve the required production volume, level processing and assembly work, and equalize product inventory.

(...) Assembly work order planning process Instructions for assembly work order that maintains leveling of each work based on daily production results.

(1) Machining work sequence planning process Instructions for machining input order synchronized with assembly progress.

QV) Line progress management processing Visual synchronization management board 8 based on moment-by-moment production results
dunning of unfinished parts by.

In the above processing, the assembly basic schedule planning processing (1) is the basis of this method, and the contents of this processing will be explained below using the example shown in FIG.

(α) Classify the required number of lots into groups to be processed through the processing process and total them by group. In this example, group A has 60 pieces.

Group B will have 60 knots.

(A) Equal spacing by group Pour into each group so that they are evenly spaced.

First, we aim to equalize the load of the processing process. In this example, ABA
B....becomes.

(C) Equal spacing by product type Furthermore, each group is made to have equal spacing in units of product products belonging to each group. This will help equalize the inventory of each product type.

By the above steps.

It is possible to create production plans that aim to equalize required production volume, processing and assembly work, and inventory by product type.

By the way, equal spacing is the basis of one-piece production planning, and the basic principle of equal spacing in the 5th order will be clarified with a mathematical formula.

Let us consider the case where there are N types of target product types and the required production amount for each is P and lots, and equal spacing is to be achieved for each product type.

Let the total production volume be represented by X.

■ becomes.

Now, the input interval from when a lot of one type t is input until the next lot of the same type is input is defined as a "distance", and this is expressed as t.

If the input interval, which serves as a reference for introducing different types of equipment at equal intervals, is defined as a distance reference, it can be determined by the distance of one type of equipment.

For example, the total production volume is 90 knots, and the production volume of variety t is 30 knots.
If so, the distance standard would be 3, and the 5-species device would be introduced every 6th day (y). If you consider the order of input, one variety of sow will be input third, sixth, and ninth.

Therefore, the input order for the lot of one type of equipment is now 'in'.
Expressed as.

Jin ``'io'' n(3) However, ``-1 + 2 +..., P, n indicates the input order for variety t.In other words, taking the input order JLn for all varieties, If you prioritize the input from the lowest input order.

The input order is set at equal intervals for each product type.

In the calculation process, the input order JY is normalized by the total production amount X,
Defining this as the normalized rank and expressing it as -)'in, the formula (
2) The following equation is obtained from (3).

(However, 71:': 1 + 2 +..., p
) Therefore, the input order that can be claimed is the normalized rank set of all varieties ()14. No, 2. ..., ),, n) (however,
t=1.2, '', N, n=1.2 . . . =, From among J, it is sufficient to sequentially input the pieces starting from the opening (y) with the smallest value.

By the way, formula (4) has a drawback that the normalized rankings of each product type input last have the same value. 'Therefore,
The following equation (5) is created by adding 1 to the denominator of equation (4) for correction, and this is used.

According to this method, the input order can be determined based on the value obtained by adding 1 to the given production amount of each product type and taking the reciprocal of this value. Therefore.

This method will be called the +1 fraction method.

This +1 fraction method can be solved by simply determining the normalized rank of each product type in advance, then targeting all products and sorting them in descending order at once. It has the characteristic that it takes a short time.

〔Effect of the invention〕

As explained in detail above, according to the present invention, it is possible to proceed with production while maintaining the required production volume, simultaneously leveling processing and assembly operations, and uniformizing product inventory. Significant effects can be achieved in reducing costs and stabilizing product inventory.

[Brief explanation of drawings]

Fig. 1 is a schematic diagram showing a comparison between the conventional method and the production system with mutual load leveling of processing and assembly according to the present invention, and Fig. 2 is an implementation of the production system with mutual load leveling of processing and assembly according to the present invention. FIG. 2 is an explanatory diagram of an example configuration. 1... Processing device, 2... Assembly work instructions, 6... Processing work instructions, 4-'i, 4-2, 4-1...
Processing line, 5... Assembly line, 6-1, 6-2
, 6-6... Processed finished product, 7... Assembled finished product, 8.
...Visual synchronization management board. Figure 1
Mouth/-1-3

Claims (1)

[Claims] 1. Based on the basic assembly schedule plan for products of various types that are mixedly produced, each product is grouped by pass processing process, and each group is spaced at equal intervals, and each product type is spaced at equal intervals within each group. The assembly work sequence planning process calculated in step 5, the processing work sequence planning process that calculates the leveled machining work for each machining process based on this, and the synchronization based on the results of the assembly work sequence planning process described above. A processing device that performs line progress management processing that outputs management data based on the assembly line work plan created from the assembly work sequence planning process and the processing line work plan created from the same processing work sequence planning process. A production system that equalizes the load on both processing and assembly to keep the production process running.