KR100260165B1 - Apparatus for automobile production process - Google Patents

Abstract

PURPOSE: A manufacturing process system of a vehicle enables to project the manufacturing sequence project of a painter factory according to the manufacturing sequence project of a trim factory. CONSTITUTION: Characteristics specification according to each kind of vehicle is made through a work order. The manufacturing sequence is projected according to the specification. Then, the manufacturing sequence of a trim factory is projected. The manufacturing sequence of a trim factory is projected. Then, the manufacturing sequence of a body factory is projected. Thus, the supplying time of parts and vehicle are regulated.

Description

Automobile production process equipment

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production process method and apparatus for an automobile, and more particularly, to a production process plan of a trim shop (TRIM SHOP) according to an ordered specification, (PULL) system which establishes the production order plan of the paint factory (PAINT SHOP) and establishes the production order plan of the body factory (BODY SHOP) and the press shop With flexible control of process flow and decentralized process control, material management, and decentralized production sequence planning for each process, the company responds flexibly to changes in material flow and process flow, reduces inventory of parts and mass-produced automobiles, The present invention relates to a production process method and apparatus for a vehicle in which an orderer delivers timely delivery to a desired date.

Generally, the automobile assembly plant consists of a main factory consisting of a car body factory, a paint factory and a trim factory, and a supply factory supplying parts necessary for the main plant. The supply factory includes presses, engines / gears, Assembly plant.

At this time, in order to increase the efficiency of the work, the car body factory and the assembling factory perform leveling of the major component consumption, and since the paint factory prefers the continuous production of the same color body, Do.

The HOST COMPUTER SYSTEM is an ORDER of the local sales network of the sales system, as can be seen from the production planning system flow chart of FIG. 7 and the production process control flowchart of FIG. 8, After collecting (Step 1), the daily production plan is set for each order specification set according to the collected contract orders (Step 2). When the process is transferred to the process system, that is, the main factory through a dedicated line, According to the production plan, an order for supply and demand of materials and parts needed for the external factory and its own factory is presented and requested for payment (Step 3).

Thereafter, the main factory sets the production plan of the body factory according to the set daily production plan (1), and instructs the press factory (2) to perform the vehicle operation for the production of each part and body mold, (Step 5, step 6), and analyzes the stock status according to the specification and designates the sequence of the vehicle for the work progress.

Then, the finished body welded to each manufactured part is temporarily stored in an intermediate warehouse called WBS (WHITE BODY STORAGE: 3) and then put into the paint factory 4 (step 7).

The paint factory 4 is painted in the lower part, middle part and upper part of the body to be charged and stored in the intermediate warehouse called the PAINTED BODY STORAGE 6 (step 8, Step 9), and put into the trim factory 7, and each part is assembled and manufactured according to the specifications ordered by the consumer, and delivered to the consumer as a finished vehicle (Step 10).

The flow of one embodiment of the progress of the production process of the automobile proceeding as described above will be described with reference to the accompanying FIG. 9.

The main plant is composed of a vehicle number and a vehicle number (VIN), a body type, a paint type, a design type (TRIM TYPE), and an order number (ORD) We set up the leveled body production plan according to the daily production plan of random number and designate the sequence of the car model and proceed the body production of the daily production plan through the press work of each part and the welding of each part that is completed press work.

At this time, for example, in a daily production plan in which an algebraic vehicle whose bin number, body number, paint type, and order number are different, such as "A" When a fault occurs in any vehicle body, for example, "122", the vehicle body in which the coupling is generated is removed from the line, the repair is restored, and the vehicle body is returned to an arbitrary point.

At this time, the process flow of the body shop proceeds sequentially according to the set daily production schedule, so that the body "123" and "124" after the arbitrary body "122" After proceeding, the order of the state passed through the body factory in the WBS storage warehouse of " C " is stored as a table such as " D " in which the order of the bin number and body type, paint type and trim type is changed.

Then, the car body stored in the WBS storage warehouse carries out a grouping (grouping) to perform consecutive painting for each paint color, and then carries out a painting process like "E" according to the stored order.

If, for example, a defect occurs in the painting of the car body 124 during the progress of the paint process for an arbitrary car body, the car body having the defect is removed from the line and restored, And the car body that has completed the painting process in the PBS storage warehouse such as " F " is sequentially stored in the order of " G ".

Then, according to the input instruction, the body stored sequentially like "G" is put into the trim factory and mounted on the engine, gear, seat, etc., and delivered to each customer as a finished vehicle.

In the conventional automobile production method as described above, since the production plan for the ordered vehicle is preceded by the body process, the re-input of the line due to the defects generated according to the progress of each process, It is difficult to meet the demand of the consumer because of the fact that it is not completed. Therefore, there is a problem that the efficient paint process can not be performed due to the confusion in the planning of the painting grouping due to the production plan of the indiscreet body factory ignoring the paint process.

In addition, when a paint factory paints an arbitrary paint, if it differs from the preceding color, the paint spray nozzle must be cleaned before the painting operation is performed. Therefore, the continuity of the work is lowered and the productivity is lowered. .

Another problem of the related art is that it is not actively performed to grasp the inventory holding amount of the parts of the planned production model and the supply and demand of the parts, so that it is not possible to load unnecessary stock parts and efficiently deliver the parts efficiently.

In addition, since the production of the automobile can not proceed with the flexible production according to the customized specifications, the continuous production is performed only for a certain type of vehicle, resulting in a waste of unnecessary manpower when surplus manpower is generated.

The purpose of the present invention is to separate the car and each specification from each contract order through the sales network, to analyze the present inventories and the material requirements, to instruct the subcontractor and its own factory to supply and deliver parts, After establishing the production order plan of the trim factory, the production order plan of the paint factory is established according to the production order plan of the trim factory established, and the production order plan of the body factory and the press factory The full-scale daily production plan to be established and the process flow of specification-to-specification exchanges provide promptness and continuity in production and timely delivery of the customer's desire.

Another object of the present invention is to establish a daily production plan for each decentralized plant, actively controlling the process flow of each vehicle body to provide a flexible response to the change of the process flow, Reduced delivery and timely supply of parts to provide efficiency in production.

It is a further object of the present invention to provide a method for grouping of a vehicle body for advancing a paint process by allowing a car body process to proceed according to a pulpit process.

According to another aspect of the present invention, there is provided a method of manufacturing a vehicle, the method comprising the steps of: preparing a characteristic specification table for each vehicle type through a work order of each sales network; A process of planning the production sequence plan of the trim factory according to the prepared specification table and a process of planning the production sequence plan of the paint factory based on the trim factory production sequence plan of the above process, And a process of planning the production sequence plan of the body factory so as to adjust the injection timing of the parts and the vehicle.

The present invention also relates to a host computer system for collecting order orders for each vehicle type and each specification of each sales network and establishing a daily production plan and a weekly production plan, and transmitting the established daily production plan and weekly production plan through a dedicated line A production management control slave system for establishing data of the production management draft and exchanging mutual information with the slave computer systems of the respective factories assigned to the plant; A trim factory control slave system for carrying out a specification exchange in the presence of a body removed from the line due to the progress of the trim process and the occurrence of defects; Painting process to control the process flow of the paint factory A factory control slave system, a body factory control slave system for establishing a production sequence plan of a body factory and a press factory in accordance with a production sequence plan of the paint factory, and controlling a process flow of the body factory and a process flow of the press factory, An input order indication control slave system for determining the pressing operation of each part and the welding process progress of each pressed part in the order of the set body process and the pressing process, A dynamic order re-setting control slave system that allows the same body type to be input to the subsequent paint process when the order is stored out of order, a color grouping control system that groups each body that has undergone pre-deposition electrodeposition so that the same color work can be performed And a painting process It characterized in that it comprises a re-order trim slave control system for the remediation In order to execute the replacement specification to the vehicle body in the completed sequentially stored PBS be made of a suitable specification for the first planned production order.

FIG. 1 is a schematic block diagram of a pooled ALC (ASSEMBLY LINE CONTROL) system according to the present invention; FIG.

FIG. 2 is a flow chart of a daily production plan according to the present invention; FIG.

FIG. 3 is a flow diagram of one embodiment of performing a daily production planning design in accordance with the present invention; FIG.

FIG. 4 is a flow diagram of one embodiment for controlling the progress of daily production planning processes in accordance with the present invention. FIG.

FIG. 5 is a process flow diagram of one embodiment that proceeds with active material supply.

FIG. 6 is a basic basic schematic diagram of an embodiment showing the flow of a pool-oriented production process in accordance with the present invention; FIG.

FIG. 7 is a schematic systematic flowchart showing the flow of a conventional automobile production plan. FIG.

FIG. 8 is a flow chart for executing control of a conventional automobile production process; FIG.

FIG. 9 is a schematic view showing the flow of a conventional automobile production process; FIG.

Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

As shown in FIG. 1, the pool-oriented ALC system according to the present invention includes a host computer system 100 provided at the center, a production control slave system 200 provided at the center of each production factory, The paint factory control slave system 220, the body factory control slave system 230, the input order instruction control slave system 231, the body factory 232, the dynamic order reconfiguration control system 221, A WBS 222, a preprocessing control system 223, a color grouping control system 224 and a trim order rebalancing control system 211.

The host computer system 100 establishes a daily production plan and a weekly production plan by collecting order orders for each vehicle type and specifications, which are applied from each sales network through a private line or an aerial line.

The production control and control slave system 200 is installed in a central control station of a production factory and receives the daily production plan and the weekly production plan established in the host computer system 100 through a dedicated line to establish the data of the production management draft , Exchanges information about the flow status of the process with the slave computer systems of each factory assigned to it.

The trim factory control slave system 210 establishes a production sequence plan for a trim factory for each vehicle type based on the production plan draft of the production control slave system 200, In case of equipment failure or other obstacles to production, the order of input of the originally designed paint factory and the trim factory is scattered. Therefore, the specification exchange is performed based on the original plan before the entry of WBS 222 and the entry of PBS 212, Adjust the plan.

The paint factory control slave system 220 establishes a production order plan for each color of each paint type of the paint factory based on the order of the production order plan of the trim factory established in the trim factory control slave system 210, Control process flow.

The body factory control slave system 230 establishes a production sequence plan of the body factory and the press factory in accordance with the production sequence plan of the paint factory control slave system 220 and controls the process flow of the body factory and the press factory do.

The injection order indication control slave system 231 performs a pressing operation of each part on the model of the process sequence set according to the control of the body factory control slave system 230 and the progress of the work progress for progressing the welding process of each pressed part Determine the timing.

The body factory 232 proceeds with the press process of each part and the welding of each pressed part under the control of the injection order instruction control slave system 231. When a defect occurs in an arbitrary part according to the flow of the process After removing from the line, they are restored in an arbitrary order to induce the progress of the subsequent process.

The WBS 222 temporarily stores the body that is being drawn in by the press process and the body process.

The dynamic order resetting control slave system 221 is used to adjust the order of the production process of the original waste plant when the body stored in the WBS 222 is stored out of the originally scheduled order due to the occurrence of defects in the flow of the body process Considering vehicles with less color grouping and buckets at the same time, re-establish the production sequence plan so that they can be put into subsequent paint processes.

The color grouping control system 224 groups each of the pre-processed and electrodeposited bodies into arbitrary numbers so as to perform an operation of the same color for an arbitrary time or amount of dyes.

The trim order rebalancing control slave system 211 is designed to be adapted to the originally planned production sequence plan for vehicles that have completed the painting process sequentially, It maintains the ordering sequence of the planned trim plant through specification exchange so that the body of the same painting and body type can be put into the trim factory.

In this case, the specification exchange performed before the entry of the WBS 222 is performed by the order of production of the body factory, such as reworking due to equipment problems or product quality problems during production of the vehicle, (WBS) 222, only the color information of the vehicles having the same body type as the same bucket number (vehicle number) without replacing the physical body is exchanged , Which is a series of logical information exchange workings in which the vehicle is to be put into the planning sequence of the first paint factory as much as possible.

In addition, the specification exchange executed before the PBS 212 is carried out may be performed during the execution of the vehicle painting operation by the order of the production order of the paint factory, or the production caused by the remodeling operation or the repair work due to the quality problem of the product To match the ordering sequence of the trim factory prior to entry into the PBS 212, which functions as a buffer for the order, the same body type as the same bucket number (paint bucket), without the exchange of the physical body for vehicles having the same color This means a series of information exchange work for exchanging only the trim option information that the vehicles have and thereby inputting the vehicle in accordance with the input sequence planning of the first trim factory.

The flow of the production process in the full ALC system of the present invention having the above-described functions will be described in detail with reference to the accompanying drawings.

As can be seen from the attached FIG. 3, the host computer system 100, which is a production overall system, collects work orders for each type of vehicle and each specification collected from each sales network, After dividing the specification data, a characteristic table of each predetermined component group for the vehicle is prepared (step 101), and a variation index and a variation code of the predetermined component group are arranged (step 102).

Thereafter, a list of design materials is created on the basis of the design basic list (step 103), a code and a table of the stencil line control method are created (step 104), and a technical specification sheet is notified simultaneously (step 105) And determines the point of application for the final change committed (step 106).

In addition, a product specification table is created based on the characteristic table of the predetermined parts group created in the step 101 (step 107). Then, in addition to the application characteristics of the product specification table, a list of specific specifications, motels, model specifications, (Step 108), the product specification table is determined and distributed (step 109), and the application time is confirmed and inputted (step 110).

Thereafter, the production specification table is created, the created production specification table is converted into a database, and the basic specification data of the work order is provided (step 111).

In addition, the host computer system 100 designs the design according to the vehicle type and specifications according to the collected work orders, and then determines the color of the vehicle body (step 112). If the new color is the new color, the host computer system 100 registers the color of the selected color, The application time point is determined (step 113).

After determining the option combination number by combining the characteristics of each predetermined part group determined above with the control method of the assembly line, the product specification table, the production specification table, the design and color of the body, and the like (step 114) (Step 115). The overall specification for production is constructed on the basis of the basic specification, the work order, and the data in the database (step 116).

Thereafter, the set work order is maintained (step 117), the entire specification file configured for production is stored (step 118), the daily production plan and the weekly production plan are established, and the established production plan is transferred to the respective factory To the production control slave system 200 provided in the control station (step 119).

The production management control slave system 200 initializes the transferred production plan to the simple factory level in consideration of the process order of the body factory and the process order of the trim factory (step 120) The leveling of the trim options, the leveling of the body options and the leveling of the color options are performed (step 121), the process order of the trim factory is established, and the established plan is transmitted to the trim factory control slave system 210 side .

At this time, a preset (RESET) formula for the leveling is determined as follows.

Intvi_Goal [j] = Sequence Quantity / j Option Number of vehicles

Cum_Output [j] = Xj, k-1

When Out_Sequence is defined as K-1 (a count number so far)

to be.

In this case, for example, if the transmitted daily production plan is as shown in the following Table 1,

[Table 1]

A production order plan is established.

The trim factory control slave system (210) divides the volume of the car body into equally spaced buckets within a certain range that does not hinder the production and supply of parts and materials, even if the production sequence plan of the trim factory is changed. (Step 122).

Then, in each of the divided buckets, according to the vehicle type and the option according to each order specification

(Step 123) to establish a production sequence plan of the actual trim factory (step 124), and the production order schedule of the actual trim factory established is set to the specifications of the work order And the grouping of the exterior colors to maintain the continuity of the production sequence order of the paint factory, and then transmits the input sequence plan to the paint factory control slave system 220 (step 125).

The paint factory control slave system 220 establishes a production sequence plan of the paint factory for proceeding the paint in its factory based on the transferred production sequence plan (step 126) and then, at regular intervals according to the established production sequence plan After the bucket is divided into an arbitrary number (step 127), color grouping is performed for each color in the divided buckets (step 128), and a production order plan of the actual paint factory is planned (step 129).

If the actual production sequence plan of the paint factory is established in the step 129, the production sequence plan corresponding thereto is transmitted to the body factory control slave system 230 through the dedicated line.

The body factory control slave system 237 normalizes the body options within the bucket of the production sequence plan of the paint factory to be transmitted (step 130), establishes a production sequence plan for the process progress of the body factory (step 131) The production process is started by advancing the body process by instructing the injection timing based on the production sequence plan (step 132).

Thereafter, the produced results are collected and checked in the production control slave system 200 through information exchanged (step 134).

In addition, the current state of receipt of the material and the status of the stock are checked in the overall specification configuration for the production of the step 116, and the yield status of the material is checked according to the production progress of the step 133, .

The operation of the schematic production process flow will now be described with reference to the accompanying FIG. 4.

As described above, when the daily production plan established by the work order collection of the sales network is transmitted to the factory through the dedicated communication network (step 201), the factory transmits the transmitted daily production plan to the entire production sequence plan (Step 202), the daily production plan is sent to the trim factory (step 203) while instructing the subcontracting factory and its own factory to submit the request for delivery of materials and parts according to the established overall production sequence plan.

The Trim plant performs leveling using the formula of the target tracing method as described above with respect to the process order of the trim factory and the leveling procedure for the process order of the body factory, And the grouping for maintaining the production order plan by applying the integrated sequence planning method.

At this time, if you want to consider more leveling than other options, use a larger number of weights as weight and a negative number as weight for color group evaluation.

Then, for the vehicles in each bucket, the production order is rearranged by applying the integrated sequence planning technique by the target tracking method considering the leveling of the process order specification of the trim factory (step 204).

At this time, only the leveling specification is applied in order to maximize the productivity of the trim plant, even if the order of the vehicles is changed in the bucket of one unit, and then introduced into the PBS.

If the bucket table for any number of bills and body types, paint types, trim types, and any determined number of orders is transferred to the paint factory, such as " a " Considers the capability of the body factory to plan the production sequence of the trim factory to establish the two-stage production sequence plan in order to maximize the productivity efficiency of the paint factory.

First, the production sequence plan of the trim factory is leveled for the leveling specifications of the body factories in each PBS bucket, and the integrated sequence planning technique, which is a target tracking method for grouping the paint factory in arbitrary units, is applied Thereby reconstructing the arrangement of the process sequence.

At this time, we do not consider leveling items of trim factory.

Then, the process sequence of the paint factory established by the application of the integrated sequence planning method is divided into the paint bucket units, and the production sequence planning is performed considering the order of painting process of the paint factory and the grouping accordingly, (Step 205).

In this case, considering only the painting process order and grouping of the paint factory, even if the order of the vehicles in the paint bucket is reversed and enters the WBS, the order can be restored before entering the WBS.

If the process sequence of the paint factory, such as the bin number, body type, paint type, trim type, and order, such as "b" of the attached FIG. 6 rearranged as described above is transmitted to the body factory via the dedicated communication network, In order to maximize the productivity, the production sequence plan of the paint factory is leveled in consideration of only the leveling specifications of the body factories within each paint bucket, and then the number of the blank numbers, body type, paint type and order A new production sequence plan is rearranged in order (step 206).

As described above, when the production order plan of the body factory is completed, the control slave systems of the respective plants according to the specification list of the work order set as described above instructs the input of the parts and the input of the vehicle, (Step 207).

121 ", " 124 ", " 123 ", " c ", etc. in FIG. 6 attached with the production of the vehicle body through welding of each part after each part is press- , "122", and "125" in the order of "d", the body process is proceeding. In this case, a defect occurs in the body of the bin number "124" When detected by the monitoring means, the body number of the bin number "124" in which the defect is generated is recovered after being removed from the line, and then re-inputted to an arbitrary line position to continuously process the subsequent process, Are sequentially stored (step 208).

At this time, the body where the defect is generated and the place to be reintroduced after the recovery are recognized by the body factory control slave system 230 of FIG. 1 attached by the data communicated with each other, and utilized as the reference data of the reordering plan.

The order of the vehicle bodies stored in the WBS is stored in the order of the bin numbers "121", "123", "122", "124", and "125" The input order indication control slave system 231 of FIG. 1 selects bin numbers "122" and "123" matching the body type in one bucket positioned on the same line, The arrangement of the bin numbers is rearranged in the order of "121", "122", "123", "124", and "125" It is convenient to take out the body for the car and improves the efficiency of evaluating the color group.

At this time, the reordered specification exchange is acknowledged to the dynamic re-ordering control slave system 221 and established in the process sequence re-ordering plan of the paint factory control drill system 220.

Subsequently, in accordance with the instruction of the paint factory control slave system 220, the body in the specially exchanged WBS enters the paint factory in the order of "121", "122", "123", "124" The preprocessing control slave system 223 of the paint factory preprocesses the entered vehicle body in a preprocessing process prior to coloring and then performs color coding for the same color in units of buckets set under the control of the color grouping control slave system 224 Grouping is carried out to carry out the painting process.

As described above, when a defect occurs in any body, for example, a blank number " 124 " in the course of the paint process due to a failure of the paint spray nozzle or a mistake of the dye mixture, The vehicle body bin number " 124 " is removed from the line, restored, and then restored in an arbitrary order, for example, after the bin number " 125 "

At this time, the flow of the process is recognized by the paint factory control slave system 220 of FIG. 1 attached by the data communicated with each other, and utilized as reference data in the process of rearranging the production sequence plan.

As described above, the car body having completed the production order planning of the paint factory is sequentially stored in the PBS, the order of which is the same as the empty numbers "121", "122", "123", "125" &Quot;, " 124 ".

At this time, the trim order rearrangement control slave system 211 of FIG. 1 of the accompanying drawings selects the bin numbers " 124 " and " 125 ", whose body type and paint type coincide with each other, Such as "i" in Figure 6, to rearrange the arrangement of the bin numbers so that the smaller the number of bins is located in front of "121", "122", "123", "124" .

This is to exchange the car body and owner who have the same body type and color type and have not yet entered the PBS, and the order of entry of the trim process, so that the customer can deliver to the desired delivery day on the desired delivery day.

As described above, when the specification exchange is completed before the PBS, the completed bin numbers are stored in the PBS in the order of PBS. In the PBS, the optimal workload leveling and the material consumption rate leveling are performed to enter the trim factory, Which leads to the release of the car.

As can be seen from the accompanying FIG. 5, the control of the flow of the supply of each part and the material in the production of the automobile having such a process is carried out in accordance with a request for supply of materials and parts Is requested by the central host computer system 300 to the respective subcontractors and their own production suppliers 320 through the dedicated communication network 310, each subcontractor and its own production vendor 320 receives orders And supplies the corresponding materials and parts to the storage warehouse 330 according to the request.

The central host computer system 300 then transmits a daily production plan to the trim factory 340, the paint factory 350 and the body shop 360 based on the daily production schedule established according to the work order, And each of the parts and materials stored in the storage warehouse 330 is put into each factory according to the progressed production plan.

At this time, the central host computer system 300 grasps the state of consumption of materials for each plant by calculating and calculating the consumed state of each part and parts of each plant at intervals of a predetermined time, To the subcontractor and its own factory.

As described above, according to the present invention, for each specification of each vehicle type by the work order in the production of automobile, the order of the trim process established in the trim factory and the order plan of the paint factory, The integrated production control method and the decentralized production planning and control of each plant and the decentralized and flexible management of materials eliminate the effect of flexible response to changes in the process, reduction of inventory and waste of idle manpower.

In addition, by separating the buckets of each unit by each factory, the production plan of each factory is autonomously adjusted. Even if a defect occurs in the process flow of each factory, it is possible to exchange the specs, The efficiency and reliability of production is provided.

Claims (1)

In a production process apparatus for a vehicle, a host computer system for collecting order orders for each vehicle type and each specification of each sales network and establishing a daily production plan and a weekly production plan, and a daily production plan and a weekly production plan, A production management control slave system that receives data from the plant management system and establishes data of the production management draft and exchanges mutual information with the slave computer systems of the respective factories assigned to the plant, A trim factory control slave system for establishing a sequence plan and performing specifications exchange when a car body detached from the line exists due to the progress of the trim process and the occurrence of defects; Establishing a production sequence plan of the factory, A body factory control slave system for controlling the process flow of the body factory and the process flow of the press factory; System, an input order indication control slave system for determining the pressing operation of each part and the welding process progress of each pressed part in the order of the set body process and the pressing process, A dynamic order re-setting control slave system that allows the same body type to be input to the subsequent paint process when the originally planned order is stored out of order, and a color grouping control system for grouping the same to perform jobs of the same color, Sequential Production process of the vehicle apparatus comprising a trim sequence remediation slave control system for the remediation In order to execute the specification in order to exchange a completed, the vehicle body painting to be produced in a suitable production specifications in the first planned order.