JP3010204B2 - Production management device - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a production process management apparatus suitable for a multi-mix production facility that produces a plurality of types of products on a single production line.

(Prior Art) For example, in a multi-mix production facility such as an automobile or an engine production facility, a plurality of types of parts and tools are prepared for each product in an assembly station arranged along the same production line. By arranging a terminal device that displays data of parts etc. corresponding to the work to be assembled from now on, by instructing the production plan to the workers, it is possible to manufacture multiple types of products on the same production line I have.

Such a production management device has a file in which centrally stored assembly part data for each process, that is, for each assembly station, and a file for storing work data for each work, and reaches each processing station based on the data of these files. A central device for designating parts to be assembled to the work is arranged, and a terminal device for displaying a command from the central device is arranged at each station.

The terminal device detects that the work has arrived at the assembly station, and sends a work arrival signal to the central device. On the other hand, the central unit receives the work arrival signal and updates the data to be sent to the terminal device. At the same time, it updates the file data of the central unit and performs a tracking operation to match the data with the actual product. Do.

By the way, at the production site, there is erroneous transmission of the workpiece arrival signal due to malfunction of the workpiece arrival detector, or removal or interruption of the workpiece, so that the production management data managed by the central unit and the processing conditions in the production line are not Will be shifted. As one means for eliminating such a shift, the site requests an operator of the central device to correct the data, transmits the data corrected by the operator from the central device to the terminal device, and based on the corrected data, A method of performing processing is used.

However, since it takes time to correct data, there is a problem in that synchronization with the manufacturing process cannot be achieved and a manufacturing error occurs.

In order to solve such a problem, there has been proposed a production management device capable of correcting data in a central device by inputting correction data from a terminal device (Japanese Patent Application Laid-Open No. 61-10 / 1986).
No. 0351), since input of correction data is performed by a field worker, there is a problem that an input error occurs or a burden is imposed on the field worker.

On the other hand, we also propose a production management system in which the barcode label with the production management data is attached to the work in the first process of the production line, and the barcode label data is read at each station to obtain the production management data. Have been.

According to such a system, it is not only impossible to transmit detailed production management data due to the limitation of the writable data amount, but also it is difficult to paste the data depending on the shape of the work. Furthermore, since data is exchanged via a recording medium, there is a problem that the flexibility of data update is low.

In order to solve these problems, a device using a semiconductor storage device as a data storage medium to be attached to a work has been proposed (Japanese Patent Application Laid-Open No. 60-16348).

That is, the central device that manages the production line checks the work with the work to be put into the line, writes the production management data to the storage medium using the terminal device in the first process of the production line, and attaches it to the work at each station. The data is read from the specified storage medium to obtain production management data.

(Problems to be Solved by the Invention) However, if a work collation error occurs in the first step, there is a problem that a work error occurs in all subsequent processing stations.

(Means for Solving the Problems) In order to solve such a problem, in the present invention,
A central device that manages production management data, and is connected to the central device via a data transmission line, and is disposed at each processing station of a production line, and stores production management data for a predetermined plurality of lots distributed from the central device. A terminal device for storing, a unit connected to the terminal device, a unit for reading production management data of a data storage unit provided on a transfer table for transferring each work, a production management data for the work of the terminal device, Data collation means for collating with the production management data of the work storage means, and when the collation results match, of the production management data from the central device or the production management data of the storage means,
Processing is performed based on the predetermined production management data, and if the collation results do not match, processing is performed based on one of the production management data from the central device or the production management data in the storage means. At the same time, the production management data of the central device is changed corresponding to the processing, and a predetermined plurality of lots are distributed to the terminal device.

(Embodiment) Therefore, the details of the present invention will be described below based on an illustrated embodiment.

FIGS. 1 and 2 show an embodiment of the present invention. A central unit indicated by reference numeral 1 in FIG. 1 receives and stores production management data from a host computer as shown in FIG. A data storage control device 11, a transfer editing control device 12, and a distribution data buffer 13 are provided.

The data accumulation control device 11 has a capacity for storing production management data for a predetermined period, for example, one day, from the host computer K, reads out the latest production management data stored therein, and stores the stored production management data. Is requested to transfer new production management data to the host computer K at the stage when all are read, and the stored production management data is searched based on the production management data input via the transfer editing control device 12. It is configured as follows.

As shown in FIG. 3, the individual production management data is obtained by assembling a date and a production order number or a lot number as an entry word, and assembling and processing conditions for each work to be produced for each production order number, such as dimensions and mounting positions. , Data indicating the type of optional parts (hereinafter referred to as execution data)
, A work number uniquely assigned to each product, and the number of products produced in each lot.

The transfer editing control device 12 includes a distribution buffer 13 having a sufficient storage capacity to store data for a plurality of lots from the data accumulation control device 11, and extracts the production management data for a plurality of lots from this. The data is distributed to the common memory 10 described later, and the production management data of the next lot after the lot currently being produced is always searched according to the data consumption of the terminal device 3, and the specified lot is distributed to the distribution data buffer 13. And is distributed to the common memory 10. That is, the transfer editing device 12 is configured to search from the head address of the distribution data buffer 13 at a fixed period to extract the production management data of the next lot after the currently produced lot.

Reference numeral 10 denotes a common memory, which is connected to the central device 1 and each of the terminal devices 3, 3, 3,.
The central device 1 and the terminal devices 3 are respectively divided into areas that can be exclusively accessed, and store production management data of the next lot after the currently produced lot at a fixed cycle, and The third and third units are configured to transmit production management data of the next lot after the currently produced lot.

The terminal devices denoted by reference numerals 3, 3, 3} are arranged in each station of the manufacturing line 4 and access an area exclusively allocated to each terminal device in the common memory 10 to indirectly access the area. The communication with the central device 1 is enabled.

Each terminal device 3 has a common memory assigned to it.
Online data controller 31 for accessing 10 areas
, An IC data control device 32, and an execution data determination control device 33
And an execution data decoding control device 34, a first memory 35, a second memory 36, and a third memory 37.

The online data control device 31 is configured to store the production management data in the first memory 35 while updating it with the production management data read from the common memory 10 and to register the updated data in the execution data decryption control device 34. .

The IC data control device 32 is configured to store the production management data read from the IC card 9 mounted on the work transfer pallet P in the second memory 36.

The execution data determination control device 33 includes a first mode in which data from the IC card 9 is prioritized, a second mode in which online reservation data in the common memory 10 is prioritized, and a third mode in which the online reservation data is compared with the IC card data. This mode selects one of the modes, and is usually set to select the third mode.

The execution data decryption control device 34 selects one of the production management data stored in the first memory 35 and the second memory 36, and when the number of units in the currently produced lot becomes zero, The production management data of the next lot stored in the first or second memory 35, 36 is read out, the processing data is extracted from the production management data, and stored in the third memory 37.

Each of these terminal devices 3, 3, 3 has a monitor control device 5
The display 6 is connected to the control unit S of the processing apparatus, and the first and second memories
It is configured to display 35 and 36 data and instructions.

The IC card control device indicated by reference numeral 7 in the figure is connected to the IC data control device 32 of each terminal device 3, and when detecting that the pallet P has reached a predetermined position,
The IC card reading / writing device 8 is operated to write data to the IC card 9 and read data from the IC card 9.

FIG. 4 shows an embodiment of a portion for executing the writing and reading of data to and from the IC card. The IC card control device 7 reads and writes data by a signal from the IC data control device 32. Transmission / reception control circuit 71 for operating the embedded device
And a storage circuit 72 for temporarily storing production management data from the IC card, and a system check circuit 73 for collating the ID card.
A transmission circuit 81 operated by a signal from the
And a transmitting / receiving antenna 83.

Returning again to FIG. 1, the IC card indicated by reference numeral 9 in the figure can be detachably mounted on a pallet, and as shown in FIG. 5, a transmitting / receiving antenna 91, a modulation / demodulation circuit 92, and an oscillator for outputting a carrier wave. 93, a command decoding circuit 94 for decoding a signal from the modulation / demodulation circuit 92, a data storage circuit 95 for storing received production management data, an ID code storage circuit 96 for storing an ID code, and a transmission / reception control circuit for controlling the operation of these circuits
97 and a battery 98 for supplying operating power to these circuits are housed in a case 99.

Next, the operation of the apparatus configured as described above will be described with reference to the flowcharts shown in FIGS.

The host computer K transfers the production management data of the product to be produced on that day to the data storage control device 11 of the central device 1. The data accumulation control device 11 transfers the stored production management data to the distribution buffer 13 (FIG. 7A) by block transfer,
Change the contents of this at once. Transfer editing controller 12
Extracts a plurality of lots, for example, 10 lots, from the next lot in the production order currently being produced from among the production management data stored in the distribution buffer 13 and
To the common memory 10 via the.

In this case, since it is the start of production, 10 lots from the beginning of the distribution buffer 13 are read and the production memory is read.
Deliver to 10.

The IC data control device 32 of the terminal device 3 arranged at the first process station of the production line 4 accesses the area of the common memory 10 allocated to the terminal device 3,
The data for writing the IC card is read, and the data is transferred to the IC card control device 7. When the pallet P on which the work is placed reaches a predetermined position (step b), the IC card control device 7 activates the IC card read / write device 8 and the production management data extracted as the distribution data by the transmission circuit 81. Is output from the transmitting / receiving antenna 83 by radio frequency.

On the other hand, the IC card 9 mounted on the pallet demodulates the radio frequency received by the transmission / reception antenna 91 by the modulation / demodulation circuit 92. After the demodulated signal is confirmed by the command decoding circuit 94 to be production management data, it is stored in the data storage circuit 95 via the transmission control circuit 97.

When the storage of the production management data is completed and the pallet P arrives at the processing station in this way, the IC data control device 32 activates the IC card control device 7 and the read / write device 8 controls the IC card 9 of the pallet P. Multiply access. The IC card 9 sends out the ID code stored in the ID code storage circuit 96 in response to the inquiry from the IC card read / write device 8, and then sends out the production management data stored in the data storage circuit 95. .

ID code received by the IC card read / write device 8,
The production management data is transferred to the IC card control device 7, and the system check circuit 73 determines whether or not the IC card is valid. If the IC card is valid, the data is temporarily stored in the data storage circuit 72. After that, the data is transferred to the IC data control device 32 of the terminal device 3. The IC data control device 32
The production management data read from the IC card 9 is stored in the second memory.
Store in 36.

On the other hand, the online data control device 31 accesses the area of the common memory 10 allocated to the terminal device 3 to read the online reservation data, and stores the read data for a plurality of lots as the production management data in the first memory 35. Store (Step b).

Since the third mode is currently selected (step E), the execution data discrimination control device 33 compares the production management data stored in the first memory 35 with the production management data stored in the second memory 36. Perform collation (step
If both production management data match, the execution data of the lot next to the currently produced lot is extracted from one of the production management data in the first memory 35 and executed. The data is transferred to the data decryption control device 34 (step nu).

On the other hand, as a result of the comparison, if a mismatch is detected between the data in the distribution buffer and the production management data of the IC card, the execution data determination control device 33 outputs to the monitor control device 5 that the data has a mismatch. And display it on the monitor 6, and at the same time, issue an alarm to urge inspection (Step).
The worker determines the cause of the abnormality based on the data displayed on the monitor 6, that is, which of the online reservation data or the production management data stored in the IC card 9 has the abnormality. If the result of this determination is that there is an abnormality in the data of the IC card 9, the operator selects the second mode by the execution data determination control device 33 (step
D) The data in the first memory 35, that is, the online reservation data is selected as the execution data (step T). If the online reservation data is abnormal, the first mode is selected (step c). 36 data points,
The data of the IC card 9 is selected (Step F) and transferred to the execution decoding control device 34.

The execution data decoding control unit 34 extracts the processing data from the production management data, decodes the processing data into a specific processing command in each station (step e), and stores the processed data in the third memory 37.
And the date and lot number attached to the machining data stored in the third memory 37 at the same time.
Transfer to the common memory 10 via 31.

Even when the data in the second memory 36, that is, the production management data from the IC card 9, is selected, the execution data decryption control device 34 extracts the processing data from the production management data and processes the data corresponding to each terminal device. Decoding into instructions and third
It is stored in the memory 37.

When the processing command is stored in the third memory 37 in this way, the control unit S of the processing device receives the supply of the processing command from the third memory 37 and causes the processing of the workpiece. When the machining operation for one work is completed (step
C) The execution data decryption control device 34 subtracts "1" from the number of units set in the lot attached to the production management data, that is, the number of units produced (step y).

In parallel with such a processing operation, at the stage where the first distribution is completed, the search pointer is returned to the beginning, and then the production management data stored in the distribution buffer 13 is currently being produced. A lot, in this case, a lot next to the production order “1”, that is, a plurality of lots, for example, 10 lots, is extracted from the area after the production order “2”, and the extracted lots are stored in the common memory 10 via the communication line 2. Transfer the common memory
The content of 10 is updated to the production management data of the production order "2" and subsequent.

As a result, when the online data control device 31 accesses the common memory 10, the content of the first memory 10 becomes 1
The new production management data is stored after being shifted by the lot.

In addition, even when the production management data is supplied from the IC card, the production management data for the product currently being produced can be grasped even in the central device 1.

Needless to say, the data necessary for the production of the lot currently in production is stored in the third memory 37, so that it does not hinder any production activity.

In this way, when the number of units set in the lot currently being produced is zero, that is, when the production of the specified lot is completed (step Y),
The execution data decryption control unit 34 shifts the data stored in the first memory 25 via the online data control unit 31, that is, shifts to the next lot after the lot currently being produced, that is, the production of the production order “2”. The management data is read (step), decoded, and stored in the third memory 37. As a result, the processing apparatus can secure data for the next production order "2" and execute production for the next lot.

On the other hand, the online control device 31
The fact that the data for the lot has been read is reported to the transfer editing control device 12 via the common memory 10. Thus, at the time when the search pointer is moved to the head of the distribution buffer 13, the transfer editing control device 12 extracts the next lot, that is, data of the production order “3” and subsequent lots, and
Deliver to 10. As a result, the production management data for the lot following the currently produced lot is secured in the common memory 10.

In the process of such an operation, the host computer K
Even if the line connecting the computer and the central device 1 or the host computer K goes down, the central device 1 stores the production management data of a plurality of lots in the data accumulation control device, and furthermore, in the production process, the central computer 1 receives data from the host computer. Since no command is required, the work of restoring the host computer K and the communication line can be performed without stopping production activities. Even if the central unit 1 goes down, the common memory
Since the production management data is additionally stored in the first memory 35 and the third memory of the terminal device and further in the third memory, the work at hand can be continued. Obviously, the production activity can be continued by switching to the IC card 9.

In this way, when the computer or the central device is restored, the transfer / edit control device 12 searches the production order of the distribution data buffer 13 based on the production order from the terminal device 3, and starts production now. Since the production management data distribution of the next production order of the lot is started, the production data stored in the distribution data buffer 13 is stored in the distribution data buffer 13 even during the production activity while the host computer K and the communication line are down. Can be grasped.

In this way, when the production of all the production management data stored in the data accumulation control device 11 is completed, the data accumulation control device 11 of the central device 1 closes the line with the data buffer 13 for distribution. Requests the host computer K for the next data transfer, and receives the next production management data from the host computer K by block transfer. Next, the new production management data is edited so that the production order in which production is being performed is first, the line is opened, and the block is transferred to the distribution data buffer 13 by block transfer.

Thereby, the transfer editing control device 12 moves the search pointer to the head at the next search timing, and distributes the production management data of a plurality of lots to the common memory 10 from the production order next to the currently produced production order. This allows
The production management data can be replenished without causing a stagnation in the production rotation.

On the other hand, if you want to change the originally planned production order,
Lots currently in production, for example, production rank "15"
, And new production management data including, for example, data of the lot number to be changed next to the production management data, for example, “17”, and transfers this from the host computer K to the central device 1. As a result, the data storage control device 11 stores the production management data of the production order “15” at the start address, the production management data of the production order “17” at the next address, and the production management data thereafter according to the production order. Then, the production management data is transferred to the distribution buffer 13 by block transfer. As a result, the distribution data buffer 13 is changed to new data whose production order has been changed. Of course, at this stage, the third memory 37 of the terminal device 3 stores the execution data of the lot currently being manufactured, so that there is no hindrance to the production activity.

In this way, when the update of the production management data in the distribution data buffer 13 is completed, the transfer editing control device 12
When the search timing comes, the search pointer is moved to the head of the distribution data buffer 13, and the lot currently being produced, that is, the lot next to the production order `` 15 '', that is, The production management data is extracted and distributed to the common memory 10. For this reason, when the set number of lots in the lot currently being produced becomes zero, the online data control device 31 accesses the common memory 10 and stores the new production management data in the first memory 35. Become. Therefore, the production in the next lot is
7 ”lot.

In this embodiment, the communication between the IC card and the terminal device is performed by radio frequency. However, it is obvious that the same operation can be obtained by using another transmission medium, for example, light beam or ultrasonic wave. Further, in this embodiment, the semiconductor storage circuit is used as the storage medium of the IC card, but it is apparent that the same operation can be obtained by using another storage medium, for example, an optical storage medium or a magnetic storage medium. is there.

(Effects of the Invention) As described above, according to the present invention, a central device that manages production management data, and a central device that is connected to the central device via a data transmission line and is arranged for each processing station of a production line, A terminal device that accumulates production management data for a predetermined plurality of lots distributed from the terminal device, and a device that is connected to the terminal device and reads production management data in a data storage device provided on a transfer table that transfers each work;
Data collating means for collating the production management data for the work with the terminal device and the production management data of the storage means for the work, and when the collation results match, the production management data or the storage means from the central device. Processing is performed based on the predetermined one of the production management data, and if the collation results do not match, one of the production management data from the central device or the production management data in the storage means. In addition to processing based on the above data, the production management data of the central device is changed in accordance with the processing and distributed to the terminal device for a predetermined plurality of lots. Not only can processing continue even if a sampling or interruption occurs, but multiple production management data are stored in each terminal device. Because, reading of production management data from the data storage means associated with the workpiece is impossible, and can be the data stored in the terminal device even if the interrupted communication with the central unit to continue working.

[Brief description of the drawings]

FIG. 1 is a block diagram showing an outline of the present invention, FIG. 2 is a block diagram showing one embodiment of a central unit and a terminal unit of the present invention, and FIG.
FIG. 4 is a diagram showing the structure of production management data used in the above device. FIG. 4 is a block diagram showing an embodiment of an IC card control device and an IC card read / write device. FIG. 5 is an embodiment of an IC card. FIG. 6 is a flowchart showing the operation of the above device, and FIG. 7 is a schematic diagram showing a data flow of the above device. DESCRIPTION OF SYMBOLS 1 ... Central apparatus, 2 ... Data transmission line 3 ... Terminal apparatus 4, ... Production line 7 ... IC card control apparatus 8 ... IC card read / write apparatus 9 ... IC card, K ... Host computer M: Processing device, S: Processing device controller P: Pallet

Continuation of the front page (72) Inventor Shin Shin Tagata 3-16-30 Sansho, Suzuka City, Mie Prefecture Inside Suzuka Technical Center, Yaskawa Electric Manufacturing Co., Ltd. (56) References JP-A-62-148140 (JP, A) Hei 1-142811 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B23Q 41/08 G06F 15/21 B65G 43/08 G06F 13/00 301 B23P 21/00 307

Claims (1)

(57) [Claims] 1. A central unit for managing production management data, and a central unit connected to the central unit via a data transmission line, arranged for each processing station of a production line, and distributed for a predetermined plurality of lots distributed from the central unit. A terminal device that accumulates production management data, a unit that is connected to the terminal device, and that reads production management data in a data storage unit that is provided on a transfer table that transfers each work; Data collation means for collating the production management data with the production management data in the storage means of the work; and when the collation results match, the production management data from the central device or the production management data in the storage means. Of the above, processing is performed based on the predetermined production management data, and when the collation results do not match, the processing from the central device is performed. Processing is performed based on one of the production management data or the production management data in the storage means, and the production management data of the central device is changed in accordance with the processing and distributed to the terminal device for a predetermined plurality of lots. Production control equipment.