KR20010106804A - Production management system using bar code system and method thereof - Google Patents

Abstract

The present invention relates to a production management apparatus and a method of the product, in particular, the status of all processes for the semi-finished or finished product by using a bar code (Bar Code), real-time monitoring and accurate information collection and processing to execute product quality An apparatus and method for improving, preventing overrun, balanced production and process minimizing inventory. It is attached to one side of Danpra Box, which is packed in a unit during the production process, with a barcode label that records the information of the product, and collected by the main computer through a network connected to each production line. It obtains production status information and promptly responds to smooth supply and demand of problems.

Description

Production management system using bar code system and method thereof {Production management system using bar code system and method

The present invention relates to a production management apparatus and a method of the product, and inputs the status of all processes using a barcode, real-time monitoring and accurate information collection and processing to improve the quality of the product, preventing overproduction, balanced production and An apparatus and method for minimizing inventory per process are provided. This is a short-range network or a remote network for collecting and processing information connected to each production line by attaching and reading bar code labels in which information of the product is recorded on one side of the Danpra Box, which is packed in units during the production process of the product. The main computer collects and processes the data to obtain production status information, and promptly responds to the appropriate supply and demand of materials required for the production process.

1 is an exemplary diagram for recording a balance of a conventional preparation.

This is a paper for manually recording the balance of the preparation to record the inventory and balance set quantity of the upper and the bottom of each model of the product. In the prior art, which relies on such manual recording, it is almost impossible to collect information in real time, and after a predetermined time, it is possible to collect information on the balance quantity for each model. When using a computer as a way to solve the inconvenience of manual labor, input is necessary and error occurs, and input speed is slow, so it is still impossible to collect and process information such as grasping balance quantity in real time. Many problems have arisen in management.

In order to solve the problems in the conventional production management, the present invention prevents overproduction by stopping the production line when an unbalanced production occurs in each process, thereby achieving balanced production and minimizing inventory by process. In addition to providing a management system and a production control method, and also to prevent data loss and errors through automatic input of basic information.

The present invention for achieving the above object is a bar code printer for printing a bar code label recording the information of the product put into the production line; A barcode inputter for reading the barcode label attached to the product of production; A terminal for performing production status input data processing according to all processes of the production line; A converter for converting a signal transmitted from the terminal in the RS-422 manner to the RS-232 manner: a line controller for processing data from the converter; A main computer corresponding to a main processing unit for collecting data from said line controller; A stop lamp indicating a production line stop signal in accordance with a control signal of the host computer; It includes.

The apparatus may further include a display device for displaying information of the line controller. The host computer also uses TCP / IP protocol to collect data from the line controller.

In addition, the production management method according to the present invention comprises the steps of printing a data such as a production model with a bar code label; Attaching the printed barcode label to a finished or semi-finished product; Scanning the barcode label affixed to a predetermined portion and inserting the barcode label into a production line; Scanning a production history with the barcode label; Transmitting the production history inputted by the scan to a line controller; Transmitting a production quantity of the production history to a display device; Displaying the production quantity on the display device; Comparing the production history with a production line stop condition; Outputting a signal for stopping the production line if the comparison result satisfies the production line stop condition; Informing the manager and the producer of the production line stop signal to the production line stop condition by the display device; Generating a production line stop state release signal to operate the production line normally; And normal operation of the production line by the release signal.

In addition, the production management method according to the present invention uses a combination representation of the department, production line, production date, work order sequence, production rank, order number, model number, model name, size classification, size, foot and foot when printing the bar code label It is characterized by.

In addition, the production management method according to the present invention does not exceed the unbalanced production standard value for stopping the production line or produce the required model after checking the input status of the previous process and grasping the production capacity for the comparison of the production line stop conditions. If the production line is characterized in that to send a stop signal.

In addition, the production management method according to the invention is characterized in that the scanning of the production line input is made by a handy (scany) scanner.

In addition, the production management method according to the invention is characterized in that the scan for the production history is made by a fixed scanner.

1 is an exemplary diagram for recording a balance of a conventional preparation.

2 is a general flow diagram of the production process according to the invention.

Figure 3a is an illustration of a bar code label attached to the semi-finished and finished products produced in each process.

Figure 3b is an illustration of a bar code label attached to the inner box (Inner Box) after production per Han Chinese in the manufacturing department.

Figure 3c is a bar code label attached to a cardboard box (Carton Box) after packing a group 12 or 6 in the product warehouse is an illustration of the unique number, destination, etc. of the cardboard box recorded.

4 is a block diagram showing a computer processing process using a bar code system according to the present invention.

5 is a block diagram showing an example of a production management system using a bar code system according to the present invention.

6 is an example of an overall network configuration to which the present invention is applied.

7 is a flowchart of a production management method using a barcode system according to the present invention.

8 is a diagram illustrating real-time monitoring of the finished product process according to the present invention.

9 is a departmental status according to the application of the present invention.

2 is a general flow diagram of the production process according to the invention.

First, check the order quantity received from the buyer and place an order for material. Shoes are largely divided into upper and bottom (outer bottom, Fini-Sole) to produce and cut the material and sewing each of the cut parts to produce the upper (201). The outer bottom is produced by dividing outsole (Outsole) and midsole (Midsole) (Phylon, PU) (202). A balance set of the produced outsole, the pylon, and the PU is identified (203), and a finish-sole (Fini-Sole) is produced (204). Check the balance set of the upper and the finish (205) and put into the production line to produce the finished product (206). After the final inspection, the product is shipped. In particular, JIT1 (203) and JIT2 (205) are essential processes for shoe manufacturers. JIT1 (203) is produced by comparing and analyzing the stock quantity by size for each model received from outsole, pylon, and PU. In the quantity that can be put into the line, the balance is released to the preparation (204) by the least common divisor. In addition, JIT2 (205), as in JIT1 (203) calculates the minimum common divisor of the stock of the upper produced in the sewing and the finish produced in the preparation and then released to the manufacturing (206). The balance of the JIT1 203 and the JIT2 205 is checked in real time, and a balanced production is performed by stopping the production line when an unbalanced production of the previous process is performed.

Figure 3a is an example of a bar code label attached to the semi-finished and finished products produced in each process is recorded the order number, model number, production department, production date, production line, size, petticoat. At the same time that this label is scanned, all the information is sent over the network to the host computer in real time.

Figure 3b is a bar code label attached to the inner box (Inner Box) after production in Han manufacturing in the manufacturing department is recorded model number, model name, color, size, etc. Unlike other departments by using a fixed scanner (Fixed Scanner) Scan

Figure 3c is a barcode label attached to a cardboard box (Carton Box) after packing 12 or 6 groups in the product warehouse, the unique number of the cardboard box, the destination is recorded. This barcode is currently being used most as a means of information input and is recognized for its effectiveness due to non-contact reading and low price without being affected by magnetic field, temperature and humidity. In addition, there is an advantage that the error is easy and small when scanning, and in particular, even when the barcode is damaged in the horizontal direction, it is possible to scan because the barcode is read in the horizontal direction. Barcodes have a constant height and can be scanned even if up to 95% of them are damaged.

4 is a block diagram showing a computer processing process using a bar code system according to the present invention.

Data such as order information, model information, production planning information, and requirement information is transferred from the host computer 401 which manages the entire computer processing to the production management system 402. At this time, the production management system 402 proceeds with the daily production plan, outsourcing production plan, bar code label printing, material requirements calculation with reference to the basic information. The production management system 402 is connected to the production by process 403 using a bar code, and the production by process 403 executes operations such as order management, production progress management, finished product management, and product inspection management. This process-specific production 403 is connected to the network 404 to perform the delivery of information and related departments, such as production management, outsourcing management, sales, quality control, material purchase. In the basic information of the production management system 402, department code, material color code, part code, customer code, door code, process code, tool code, etc. are registered and managed, and work orders are issued in daily production plans and outsourced production plans. And print barcode labels. Looking at the work history in the production by process (403), the order management is the production and delivery of orders / model / style (Tracking), the order tracking (Tracking), etc., the production progress management is the production status, balance status , Line stop status, etc., and finished product management includes incoming and outgoing orders by order, incoming and outgoing orders by destination, grasping A and G grade inventory, overproduction status, and inspecting products. Work is carried out with inspection details, defect status and rejection rate.

5 is a block diagram showing an example of a production management system using a bar code system according to the present invention. This is the configuration of an example of a production management system using a bar code (210) of Figure 2 equipment and functions are as follows.

The line controller processes 501 production process data. The converter converts the information transmitted as the RS-422 signal from the terminal to the RS-232 signal (502). The terminal processes (503) production status scan data of all lines in the process (503). The Handy Scanner reads a barcode label attached to a Danpra Box (504). A barcode label attached to an inner box of a fixed scanner is read (505). The display board displays the production quantity in real time (506). The stop lamp displays a production line stop signal (507). The Danpra Box is a box 508 for packing semi-finished products in 12-group units. An inner box is a box 509 for packing a finished product in a group 1 unit.

6 is an example of an overall network configuration to which the present invention is applied.

It is a configuration for collecting and processing information between unit workplaces using the main communication network. The information of the unit workplace is inputted to the main computer of the head office through the main communication network, and the main computer is provided to terminals that need production management and information analysis of the unit workplace. It consists of a system for transmitting and receiving data.

7 is a flowchart of a production management method using a barcode system according to the present invention.

This is a flow chart of the production management method using a bar code system. Work orders are processed by manufacturing and standards according to line targets, models of production products, and production target quantities by model, which are transmitted from the production management department. The work order is automatically generated (701). The bar code label (see Fig. 3a) recording the production information is printed by the work order 701 (702). The printed barcode label is distributed to the semi-finished production department (703). The barcode label is attached to a predetermined portion of the side of the short plastic box (see 508 of FIG. 5) before being put into the line (704). The person in charge of the production line scans the bar code label attached to the side of the short plastic box of the semi-finished product input by using a handy scanner (705). Semi-finished products put into the production line are produced in different forms of semi-finished products through various processes through a conveyor (706). The inspector at the end of the production line inspects the condition of the produced semi-finished product, if it is defective, loads it separately and keeps it. The genuine product is packaged into 12 groups using the Danfra box (707) and the barcode label attached to the side of the Danfra box is scanned (708). The bar code label scan (705, 708) data is transmitted to the information required for each department through a local area network (LAN), and also to the production management system (see 402 of Figure 4) to produce the results of the model Save it. Semifinished products produced in sewing (see 201 in FIG. 2) and preparation (see 204 in FIG. 2) are received in JIT2 (see 205 in FIG. 2) (709), and the production management system performing a comprehensive analysis is balanced production inspection. (Balance Check) is executed (710) (see FIG. 9B).

At this time, the received quantity of upper and fini-sole by model is added to the inventory quantity and analyzed. After the upper production is unbalanced, input of line by sewing (refer to 201 in FIG. 2) is performed. Check the current status to determine the quantity that can be produced immediately. The production management system sends a stop signal to the production line in order to stop production when the required model is produced and the balance is checked again to produce the required model (711). The production line stop signal is transmitted to the display device (refer to 507 of FIG. 5) to generate a disproportionate production to the manager and the producer through the operation of the warning sound and the stop lamp, thereby informing the reason that the production line needs to be stopped (712). ).

The disproportionate production reference value for the stop of the production line is the sum of the upper and the Fini-Sole for each model by summing the quantity of the two of the larger value and compare the small value. At this time, when the small value is 70% or less of the large value and the balance ratio is 50% or less of the large value, the production line is stopped.

(Example 1)

Size 6 6.5 7 7.5 8 8.5 9 9.5 Total

Upper 12 12 12 12 16 12 12 12 100

Fini-sole 6 6 9 12 12 12 6 6 69

Balance 6 6 9 12 12 12 6 6 69

(Example 2)

Size 6 6.5 7 7.5 8 8.5 9 9.5 Total

Upper 24 24 16 12 24 100

Fini-sole 9 9 7 12 12 12 6 12 79

Balance 7 12 12 12 6 49

For example, if the Upper has 100 groups and the Fini-sole has 69 groups (Example 1), or if the upper and the Fini-sole balance is 49 groups (Example 2) This corresponds to the production line stop value. As such, when the cause that meets the production line stop condition occurs, the production line stop state is displayed through a beep and a screen of the line controller (control PC-501 of FIG. 5) so that the manager and producer can recognize the cause. . This warning sound is activated for a predetermined time, for example 30 seconds, and the red stop lamp is turned on repeatedly for a predetermined period, for example 1 second, and then operated for a predetermined time, for example 1 minute, and then turned on until a release signal comes in. Will be. In order to release the suspension of production line, the meeting of the heads of the production departments will be held, the cause analysis and countermeasures will be established, and the production management will be notified.

When the action for releasing the production line stop state is completed, the reason for the production line stop, the responsible department, the release processing details, the person in charge, and the like are inputted into the line controller (control PC-501 of FIG. 5). At this time, it is transmitted to the production management system through the network and the production management system sends a release signal. The stop lamp then goes out and the production line is restarted.

As described above, the present invention can prevent unbalanced production by installing a bar code system on the production line and immediately stopping the production line when a situation that meets the conditions of the production line stop occurs. Real Time) has the effect of obtaining production status information.

8 is a diagram illustrating real-time monitoring of the finished product process according to the present invention.

In FIG. 8, part 801 shows manufacturing and total production target (Target), production quantity (Production), target-to-production ratio (Ratio) and production date, and production target by line, production quantity target-to-production ratio, and the like. The part 802 shows an order number, a model number, a model name, and a production quantity for each time line of the line selected in the part 801. In the part 803, the production quantity for each size of the model selected in the part 802 is displayed. Also, part 804 is displayed by selecting a production date and graphing the total production quantity for a specific period.

9 is an example showing the current status of each department according to the application of the present invention.

9A is a screen of order registration, inquiry, modification, deletion, and printing received from a buyer. 9B is an inquiry screen of balance automatically calculated by the production management system. A part 901 is a sum of the balance of upper and fini-sole necessary for manufacturing and production (see 206 of FIG. 2), and part (901) shows the content of the (901) by size. It is shown. Part 902 is a sum of the balance of the outsole, Phylon, and P.U, which are necessary for preparation and production (see 204 of FIG. 2), and part 904 is the size of the content of the (902). Figure 9c is a screen for querying the inventory quantity by grade (A Grade, B Grade, before inspection) of the product warehouse. 9d is a shipping status inquiry screen for each order received from the buyer.

The present invention shows the production status and inventory of all processes from materials to semi-finished products in real time on the display device and monitor by the production control device and method of the product, and quickly grasps the production status and the quantity of the inventory and reflects it in the plan. This minimizes lead time from material to shipment. Since the production status of each department is displayed in each unit process at every moment, all departments can share the production information at the same time, so that a smooth production plan can be established. Production data is aggregated and captured in real time, improving oversight and preventing overproduction and shortening aggregation times. In addition, the production status can be easily grasped by each unit and immediate action can be taken in case of problems.

Claims (8)

A barcode printer for printing a barcode label recording information of products put into a production line; A barcode inputter for reading the barcode label attached to the product of production; A terminal for performing production status input data processing according to all processes of the production line; A converter for converting a signal transmitted from the terminal to the RS-422 method to the RS-232 method; A line controller for processing data from the converter; A main computer corresponding to a main processing unit for collecting data from said line controller; A stop lamp indicating a production line stop signal in accordance with a control signal of the host computer; Production management device using a bar code system comprising a. The method of claim 1, A display device for displaying information of the line controller; Production management device using a barcode system further comprising. The method of claim 1, The host computer using a TCP / IP protocol to collect data from the line controller; Production management device using a barcode system characterized in that. Printing a production model or the like with a bar code label; Attaching the printed barcode label to a finished or semi-finished product; Scanning the barcode label affixed to a predetermined portion and inserting the barcode label into a production line; Scanning a production history with the barcode label; Transmitting the production history inputted by the scan to a line controller; Transmitting a production quantity of the production history to a display device; Displaying the production quantity on the display device; Comparing the production history with a production line stop condition; Outputting a signal for stopping the production line if the comparison result satisfies the production line stop condition; Informing the manager and the producer of the production line stop signal to the production line stop condition by the display device; Generating a release signal for stopping the production line so that the production line can be normally operated; Normal operation of the production line by the release signal; Production management method using a bar code system comprising a. The method of claim 4, wherein Using a combination representation of a department, a production line, a production date, a work order sequence, a production order, an order number, a model number, a model name, a size classification, a size, a quorum, etc. when the barcode label is printed; Production management method using a bar code system characterized in that. The method of claim 4, wherein To check the input status of the previous process and to determine the production capacity for comparison of production line stop conditions, and to send a production line stop signal if the production line exceeds the unbalanced production standard value or does not produce the required model; Production management method using a bar code system characterized in that. The method of claim 4, wherein The scan of the production line input is made by a handy scanner; Production management method using a bar code system characterized in that. The method of claim 4, wherein The scan of production is made by a fixed scanner; Production management method using a bar code system characterized in that.