JPS63256341A - Productive system of flow shop for mixing multi-type articles - Google Patents

Abstract

PURPOSE:To improve the productive efficiency of the whole line by detecting bottle neck processes from pitch time and determining the use assignment of production unit group for this process to drop the pitch time for the bottle neck process. CONSTITUTION:Actual result time in respective production processes 5a-5c is input and the input actual production result data are temporarily stored in a actual production result storing section 1b. On the basis of said data thus stored, and production process having the maximum pitch time, together with a pitch time calculation section 1a for figuring out pitch time (time interval of attained actual productive result) at respective production processes 5a-5c is determined as a bottle neck production process on production (bottle neck process detecting section 1c). To drop the pitch time to the bottle neck production process, the production equipment 7 for this process is assigned to the preparatory operation for redistribution, removable attachment of workpiece and mounting the exchange of jig tool set in response to the operative amount by article type groups.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a production system in a mass-production factory, and in particular, the present invention relates to a production method in a mass-production factory, and in particular, there are many types of products, many identical or similar types of manufacturing equipment are used in each process, and the production line The present invention relates to a multi-product mixing flow shop production system suitable for production plants that produce products in various formats.

[Conventional technology]

Conventionally, in production systems where the time required for each process is different, as described in Japanese Patent Application Laid-Open No. 60-233763, there is a means for creating data regarding the actual output of at least one process, and a standard for a standard process. A means for creating data regarding trading volume, a means for inputting upper and lower limit values of a balance coefficient, a means for calculating a balance coefficient obtained by dividing data regarding a standard height regarding actual trading volume by data regarding a standard trading volume; A production process line balance management system has been proposed that includes a display device that displays the balance coefficient and its relationship with upper and lower limit values.

[Problem that the invention attempts to solve]

The above-mentioned conventional technology merely provides information and does not give consideration to the means to utilize this information, and production is dependent on the operator who receives the information, making management difficult. There were problems such as individual differences in accuracy and the need for an operator or judge.

An object of the present invention is to provide a multi-product mixing flow shop production system that solves the problems of the prior art described above and makes it possible to improve the production efficiency of the entire line.

[Means for solving problems]

The above purpose is to provide a work performance data input means for inputting the work performance of each production process in a blow shop production system in which production is performed through a plurality of production processes, and a work performance data input means for inputting work performance data from the work performance data input means. A work performance data storage means for storing, a pitch time calculation means for calculating a pitch time in each production process based on the work performance data from the work performance data storage means, and a pitch time calculated by the pitch time calculation means. A bottleneck process detection means detects a bottleneck process in production, and in order to reduce the pitch time for the bottleneck process detected by the second bottleneck process detection means, the usage allocation of the manufacturing equipment group for this process is determined. A bottleneck process countermeasure means to be determined, a work instruction means that issues work instructions based on the countermeasure contents of the bottleneck process countermeasure means, and workpiece attachment/detachment, jigs and tools installation/replacement, etc. are performed based on instructions from the work instruction means. This is achieved by providing zero setup means.

[Effect]

The present invention inputs the production performance of each production process in real time, automatically collects the production performance time, and temporarily stores the input production performance data. Based on the production performance data accumulated through these steps, the pitch time (the time interval at which the production performance is updated) for each production process is calculated, and the production process with the maximum pitch time is This was determined to be the bottleneck production process, and in order to reduce the pitch time for this bottleneck production process, the manufacturing equipment for this process was redistributed according to the amount of work by product group, and workpiece loading and unloading and jig and tool set changes were implemented. It instructs setup work such as installation/replacement.

Therefore, in the present invention, all production processes on the line are monitored, and all production on the line is performed by centrally redistributing manufacturing equipment and setting up work to reduce the pitch time only in the bottleneck process. The production efficiency of the process can be improved.

〔Example〕

1 to 5 showing one embodiment of the present invention will be explained below.

In FIG. 1, 1 is a host computer, which includes a production performance data storage section 1a, a pitch time calculation section 1b,
It has a bottleneck process detection section 1e and a bottleneck process countermeasure section 1d. Reference numeral 2 denotes a conveyor control controller, which controls the physical distribution of production target works (not shown) transferred by the main conveyor 4. Reference numeral 3 denotes a plurality of barcode readers, which are installed as production results (production time) input means between each production process of the main conveyor 4, and detect the flow of workpieces to be produced in each production process 5a, 5b, and 5c. , each production process 5a, 5b.

5c is inputted as the production result, outputted as an interrupt to the host computer 1, and temporarily stored in the production result data storage section 1a. 5a.

5b and 5c represent the production process, and each of them is a lead-in conveyor 6a that once branches from the main conveyor 4 and then merges with the main conveyor 4.
, 6b, 6c, manufacturing equipment 7a, 7b, 7c, and a setup device for setting up workpiece attachment/detachment, jigs and tool sets, etc.! 8at 8b# 8e. The pitch time calculation unit 1b in the host computer 1 calculates each production process 5a, 5b in a regular cycle based on the production performance data stored in the production performance data storage unit 1a.
, 5c is calculated. The bottleneck process detection unit 1c detects the production process 5a, 5b, or 5c that has the maximum pitch time among the pitch times calculated by the pitch time calculation unit 1b, and uses the result as a production process, for example, as shown in FIG. Create a separate pitch time diagram. In other words, the pitch time diagram by production process shown in Figure 5 shows the pitch time by type of work in each production process when the horizontal axis shows the type of work in each production process and the vertical axis shows the pitch time by type of work. The diagram also shows bottleneck tasks. The bottleneck process countermeasure department 1d
is the bottleneck process 5a, 5b, or 5 for the bottleneck effect process 5a, 5b, or 5c detected by the bottleneck process detection unit 1c.
The usage allocation of the manufacturing equipment group 7a, 7b, or 7c of c is determined so as to reduce the pitch time of the manufacturing equipment group 7a, 7b, or 7c according to the amount of work of the work to be produced. For example, a case will be described in which it is assumed that the second production process 5b is determined to be a bottleneck additional process, as shown in FIGS. 2(a) and 3(b). In this case, the second production process will continue to include A group and B group.
It is assumed that only the workpieces to be produced that are classified into groups are flowing, and the criteria for classifying the workpieces to be produced are as follows:
It is based on the similarity of setup work.

Now, as shown in Figure 2 (a), the proportions of Group A and Group B in the target production volume in the previous cycle (7th period) are set to 60% and 40%, respectively, and Figure 2 (b)
), among the five manufacturing devices 7b to produce this, the number assigned to group A is three,
The number of units allocated to the group was determined to be 2 units, and the units produced were A in the next cycle (7th child period).
group.

If the ratio of the respective production volumes of Group B is changed to 80% and 20% as shown in FIG. As a result, as shown in Figure 3(b), it is decided that one unit will be used for group B, and as a result, as shown in Figure 3(b), units 1 to 3 will be used exclusively for group A, unit 5 will be used exclusively for group B, and 4 units will be used exclusively for group B.
The A car will be used for both 8-car groups.

In this way, when the bottleneck process countermeasure section 1d takes countermeasures and sends the countermeasure contents to the conveyor control controller 2, the conveyor control controller 2 recognizes the classification group of the production target work inputted from the barcode reader 3. It recognizes this, controls the main conveyor 4 and the pull-in conveyor 5b, transfers the target work to the No. 4 machine, and instructs the setup device 8 to attach and detach the work and replace the jigs and tools in the No. 4 machine.

Since the multi-product mixing flow shop production system according to the present invention is configured as described above, the processing method will be explained next with reference to the computer processing flowchart shown in FIG.

The pitch time calculation unit 1b reads production performance data from a certain period of time before the present time from the temporarily stored production performance data, and calculates the average value of the time required for production in each production process based on the read production performance data. Calculate and use this as the pitch time.

The bottleneck process detection unit 1c detects the maximum production process among the pitch times of all production processes, and defines that production process as the bottleneck process = The bottleneck process countermeasure unit 1d detects the production process scheduled for future production □. The production volume for each product group is determined from the work data, and the manufacturing equipment to be used is allocated according to the ratio of production volume for each product group, and the setup equipment for the manufacturing equipment that serves both groups is commanded to load and unload workpieces. and make arrangements for jigs and tool sets.

〔Effect of the invention〕

According to the present invention, when many types of products with different working times are flowed on the same line, a drop in production efficiency due to an unbalance in the amount of work between processes, which could not be avoided with conventional methods, can be avoided in the production process. This can be avoided by detecting bottleneck processes by focusing on the pitch time required from the work performance of , and reallocating manufacturing equipment by product type group to reduce the pitch time of the bottleneck process.

In other words, by centrally managing the production process at one location,
This has the effect of increasing the production speed of the entire line.

[Brief explanation of drawings]

FIG. 1 is a configuration diagram of a multi-product mixed flow shop production system according to an embodiment of the present invention, and FIGS. 2 and 3 show an embodiment of the bottleneck process countermeasure department shown in FIG.
) is the production volume ratio by product group, (b) shows the distribution of manufacturing equipment by group, Figure 4 is a flowchart of the computer processing shown in Figure 1, and Figure 5 is the production volume ratio by product group.
FIG. 3 is a pitch time diagram for each production process displaying results from a pitch time calculation unit and a bottleneck process detection unit shown in the figure. DESCRIPTION OF SYMBOLS 1... Host computer, 2... Controller for conveyor control, 3... Barcode reader, 4... Main conveyor, 5... Production process, 6... Lead-in conveyor, 7... Manufacturing Device, 8... setup device.

Claims (1)

[Claims] 1. In a flow shop production system in which production is performed through multiple production processes, a work performance data input means for inputting work performance data for each production process, and a work for storing work performance data from this work performance data input means. performance data storage means; pitch time calculation means for calculating pitch time in each production process based on the work performance data from the work performance data storage means; bottleneck process detection means for detecting a bottleneck process;
A bottleneck process countermeasure means that determines the use allocation of the manufacturing equipment group for this process due to pitch time drop for the bottleneck process detected by this bottleneck process detection means, and the countermeasure contents of this bottleneck process countermeasure means A multi-product mixing flow shop characterized by comprising a work instruction means for issuing work instructions based on the work instruction means, and a setup means for attaching and detaching workpieces, replacing jigs and tools, etc. according to commands from the work instruction means. Production method.