JP3352767B2 - Production order management system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an assembly (production) suitable for use in controlling a production line of a vehicle, especially an engine assembly process.
It relates to a ranking management system.

[0002]

2. Description of the Related Art Conventionally, production systems incorporating FA (factory automation) technology have become widespread in the manufacturing industry, and have brought great results to the manufacturing industry in improving product quality, reducing manufacturing costs and improving productivity. According to a production system in which this kind of FA technology is introduced, the transfer of a workpiece and the control of processing are all performed under the control of a computer. That is, under the control of the computer, the workpiece is sequentially conveyed to various types of processing machines, and each processing machine is provided with control data determined according to product specifications and the like. Then, the processing machine performs processing control according to the control data. In this way, a target product is automatically produced.

In a production system using the above-described FA technology, a workpiece is usually conveyed sequentially among a plurality of processes and processed by the various processing machines described above. For example, in the case of producing a vehicle, each part, engine, vehicle body, and the like are manufactured through individual processes and finally assembled to complete an automobile. Further, in this production system, the production schedule and the production amount of the workpiece in each process are managed by making a production plan for each production process.

For example, an engine assembly process (hereinafter referred to as AE)
(Referred to as an (assembly engine) line), a production plan is set up in time for the production timing of a body assembly process (hereinafter referred to as an AF (assembly frame) line) following the AE line. .
Similarly, in a machining section process which is a process preceding the AE line, a production plan is drafted in accordance with the process content of the AE line.

[0005] That is, in the vehicle production line, first, the production of the AF line is planned based on the delivery date and the sales plan of the vehicle ordered by the user, and then the production of the AE line, which is a pre-process of the AF line. A plan is made. In this way, by consistently drafting a production plan for each process, a just-in-time production mode is achieved, and the productivity is improved.

[0006]

By the way, in the conventional assembly order management system, since the production planning and the creation of the assembly order are performed manually, a large number of man-hours are currently used. Moreover, in recent production forms, small-volume production of many kinds of products has progressed, the conditions to be considered have increased, and the judgment materials have become complicated. In the case of manual work, more work is required to create the assembly order (production plan). I need. After all, since the current assembly order management system still relies on human labor, there is a long-awaited demand for a system that creates an engine assembly order adjustment extremely efficiently in consideration of various conditions.

In the conventional assembly order management system,
The order of assembly on the AE line was set based on only the specifications and number of engines required on the AF line for the day. That is, the order of assembly has been set ignoring the time at which the engine to be assembled is used on the AF line, the time required for assembling the engine, and the like. Accordingly, in order to avoid a situation in which there is no engine to be assembled in the AF line (hereinafter, referred to as a shortage), it is necessary to maintain an unnecessarily large inventory, which is uneconomical.

The present invention has been made under such a background, and provides an assembly order management system capable of efficiently adjusting a production order while considering various judgment conditions including time and time. The purpose is to do.

[0009]

A production order management system according to the present invention has a downstream line for assembling a product in lot units using a plurality of types of parts continuously produced in lot units in an upstream line. Used for production lines
A production order management system that manages the order of production of the parts, comprising: a production start time and an end time for each lot of the product, a downstream order file storing part specifications of each part used in the product as a set, Production start time and end time for each lot of the product in which each part is used, parts specification of each part, and lot set for production
An upstream ranking file storing the standing time as a set,
When the production start time for each lot is earlier or the production start time is the same, the production order is assigned to the set in the upstream order file in the earlier production end time for each lot. the production start time and end time of each part stored in the set is calculated based on the plant essential time according to the rank, rank creation to calculate the difference between the end time and production start time of the each lot Means,
A lead time indicating how much the production end time of the parts used in each lot precedes the production start time of each lot is set in advance, and when the difference is less than the lead time, the production And a rank changing means for changing the rank.

[0010]

According to the above arrangement, in the order creating means, if the production start time for each lot is earlier or the production start time is the same, the production end time for each lot is earlier in the upstream order file. Are ranked in production order. The set includes a production start time and an end time for each lot of a product using each part, a part specification of each part, and a lot assembly time required for production,
It is created based on a production start time and an end time for each lot of the product and a set in a downstream order file having component specifications of each component used in the product. Further, in order to create unit, the production start time and end time of each part stored in the set in accordance with the production order is calculated based on the between the time the plant essential <br/>, the lot this end time The difference from each production start time is calculated. In the order changing means, a lead time indicating how much the production end time of the parts used in each lot precedes the production start time of each lot is set in advance, and the difference is less than the lead time. If not, the production order is changed. Thus, the production order is adjusted efficiently while taking into account various judgment conditions including time and time.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A: Configuration of the Embodiment An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a diagram showing a functional configuration of an assembly order management system (production order management system) 1 according to an embodiment of the present invention. In this figure, HST transmits and receives various data (described later) to and from the assembly order management system 1. Is an out-of-line system that performs processing such as ordering various parts required for assembling the engine in accordance with the engine assembly order determined by the assembly order management system 1.

In the assembly order management system 1, f1 is a calendar file, and the host computer HST
Is created based on calendar information (operating schedule information of each production line) supplied from. f2 is an AF assembly order file, which is created based on various data including AF assembly order information (information related to the order of vehicle assembly on the AF line) supplied from the host computer HST.

On the AF line (downstream line), a plurality of vehicles having the same specifications are collectively handled in units called "lots" so that production activities are performed efficiently. Therefore, the above-described AF assembly order information and the AF assembly order file f2 have order information for each vehicle body lot. Reference numeral f3 denotes an engine assembly order file in which engine assembly order information on the AE line (upstream line) is recorded.
1. Created based on the AF assembly order file f2 and various data supplied from the host computer HST.

That is, the assembly order management system 1 creates an engine assembly order file f3 based on the calendar file f1 and the AF assembly order file f2, and assembles the engine according to the engine assembly order file f3. A predetermined process is performed. This assembly order management system 1
AF line for assembling the car body as shown in Fig. 2
It is applied to the AE line AEn (n is the AE line number) that assembles the engine to be supplied to AFn (n is the AF line number), and is installed in the factory together with the equipment for performing each operation of the AE line AEn. You.

Before the description of the assembly order management system 1, the AE line to be processed by the system 1 will be described.
AEn and AF line AF which is a subsequent process of this AE line
n will be described. In this embodiment, four A
E lines AE1 to AE4 are installed, and each AE line
AE1 to AE4 have a plurality of assembling steps for assembling the engine. In each of these steps, an assembling operation is performed according to the specifications of the engine to be transported.

(1) AF Line AFn The AF line AFn is set in accordance with the assembly order described below.
The body of the corresponding model and the AE line AEn supplied from the previous process
Is a process line for assembling the engine (completed engine) assembled in the above according to a predetermined procedure. FIG.
FIG. 4 is a diagram showing a daily assembly order in each AF line. In this figure, AF1-1, 1-2 to AF4-1, 4-
Reference numeral 2 denotes an AF line, and times t ₁ and t ₂ indicate times when the AF lines AF1-1 and 1-2 to AF4-1 and 4-2 start or end the assembling work. Here, eight AF lines AF1-1 and 1-2 to AF4-1 and 4-2 are provided, and FIG. 4 shows each AE line AEn in this production system.
1 shows an example of an assembly order for one day.

A, B, C,..., Shown in FIG.
A ′ and a ′ indicate the classification of the vehicle model supplied to the line. Also, AF lines AF1-1 and 1-2 to AF
Combinations of 4-1 and 4-2 with the AE lines AE1 to AE4 are freely performed. That is, each of the AE lines AE1 to AE4 has the same process. Further, there are various types of engines with different specifications, and engine components to be assembled are different depending on the specifications. For example, an engine of a certain specification needs to be processed in all the processes of a certain AE line described above, and an engine of another specification does not require some processing or parts. Therefore, in the AE lines AE1 to AE4, the AF lines AF1-1, 1-2 to AF4-1,
As in 4-2, multiple engines with the same specifications are handled as one "lot", and processing is performed in the necessary steps according to the specifications.

(2) AE line AEn Here, the AF lines AF1-1, 1-2 to AF4-1, 4-
4 AE lines AE based on the assembly order of the day in 2
The conditions considered when creating the assembly order of 1 to AE4 will be described below. Advance time Normally, the engine assembly on the AE lines AE1 to AE4 is performed in advance of a predetermined time, and the completed engine is mounted on the AF lines AF1-1 and 1-2 to AF4-1 and 4-2, which are the body assembly process.
Supplied to Here, "preceding" means that the time when the lot of the corresponding engine is line-off from the AE line AEn precedes the time when the lot of a certain vehicle line turns on the AF line AFn, and the "preceding time" Is A
The AE-OFF time of the completed engine from the AE lines AE1 to AE4 is subtracted from the AF-ON time when the vehicle body and the engine are put into the F lines AF1-1 and 1-2 to AF4-1 and 4-2. Say time.

The preceding time is determined by the AF lines AF1-1 and AF1-2.
-AF4-1 and 4-2 have extra parts, such as completed engine, necessary for vehicle body assembly.
Decisions are made where conflicting conditions are met, such as enhancing safety so that 1, 4-2 does not stop, and reducing the inventory of the complete engine alone (stock quantity) and putting it on the production line efficiently. Therefore, for example, this leading time is set to 1
When the time is half an hour, each AF line AF1-1, 1-2 to AF4-1
, 4-2, the number of units equivalent to the time (for example, two hours) that is sufficiently longer than the preceding time is recorded as the “number of pre-assembled units (pre-production units)” on the next day, and the AE lines AE1 to AE4 It is set at the end of the assembly order of the day. Here, AF to the time from the time t ₁ shown in FIG. 3 to time t ₂
The number of engines mounted on the vehicle body line-on to the lines AF1-1, 1-2 to AF4-1, 4-2 is the pre-assembled number.

As described above, the AE lines AE1 to AE1 to AE1 to 4-2 are considered in consideration of the daily production plan in the AF lines AF1-1 and 1-2 to AF4-1 and 4-2 and the above-mentioned pre-assembled units. Approximate daily production of AE4 is required. However, this approximate daily production volume is obtained based on the production plan of AF lines AF1-1 and 1-2 to AF4-1 and 4-2, and the approximate daily production volume corresponding to each AE line AE1 to AE4. Varies. Further, there is a difference between the approximate daily production number of the entire AE line obtained by summing the approximate daily production numbers corresponding to the respective AE lines AE1 to AE4 on the same date, and the approximate daily production number on different dates. This “variation” reduces production efficiency,
In order to increase the burden on the workers engaged in each production line, it is necessary to minimize the load. That is, it is necessary to equalize the daily production volume. Therefore, the level of daily production is leveled by the two methods described below.

(A) Method using KD lot For example, when supplying a completed engine to a factory in a remote place, the engines produced on the AE lines AE1 to AE4 are used for the AF lines AF1-1, 1-2 to AF4-1. , 4-2. These engines are produced as a "KD lot (non-supply lot)" in one lot. By adding this KD lot to the production plan of the AE line AEn on the day when the approximate daily production is less than the average value per month as shown in FIG. 4, the daily production is leveled.

(B) Method of using added lots Alternatively, the average value (average number) of the number of Nissan vehicles for each AE line during the period (processing period) during which the assembly order management system 1 operates is calculated. In the month in which the number exceeds the standardized number, the production number exceeding the standardized number is allocated to the month less than the standardized number, and this is set as the added lot of the corresponding month. That is, the production quantity exceeding the standardization quantity is advanced and the production quantity is increased to achieve the leveling of the daily production quantity. The AF lines AF1-1, 1-2 to AF4-1,
The vehicle body and the engine are assembled according to the order of assembly of the 4-2 and the AE lines AE1 to AE4.

Referring now to FIG. 3, the AF lines AF1-1, AF1-1,
The assembly order of 1-2 to AF4-1 and 4-2 will be described. According to this production plan, for example, the AF line AF1-1
Between t ₁ to time t _2, the producing vehicle A model assembles the engine produced by the AE line AE3 to the vehicle body. Time t ₂ Thereafter, using the engine to be supplied from the AE line AE3, assembling B type and C type in order.

Incidentally, as described above, the AE line AE1
To AE4 are supplied to the following AF lines AF1-1 and 1-2 to AF4-1 and 4-2 as appropriate, where the production plan created based on vehicle order data and the like is created. Is mounted on the vehicle body according to. Therefore, the subsequent AF line AF
A major premise of this assembly order management system is to make a production plan for each AE line in time for the AF-ON time to be input to 1-1 and 1-2 to AF4-1 and 4-2. . A specific method for determining the engine assembly order will be described later.

Hereinafter, the configuration of the assembly order management system 1 will be described with reference to FIG. 1 again. In the figure, a host computer HST controls the entire production line of the vehicle, and includes a CPU, a ROM and a RA (not shown).
M and the like. The ROM stores a control program which will be described in detail later. In addition to the assembly order management system 1, the automatic production line incorporates, for example, a vehicle body assembly system for making a production plan for the AF lines AF1-1 and 1-2 to AF4-1 and 4-2.

. WT, WT... Are work terminals, and at least one WT is arranged in each production line. Between the work terminals WT, WT... And the host computer HST,
It is connected via a communication line. The storage device (not shown) stores control data of the assembly work performed on each production line, various assembly order files including work data such as the order, contents, and quantity of the assembly work based on the production plan. are doing.

When data is transferred from the host computer HST, for example, the work terminals WT, WT. . . Gives the control of the work to each process of the AE line AEn under its own control, and specifically gives instructions such as whether or not the work can be performed and the contents of the work. Further, when an operation such as correcting data indicating the work content is performed, the work terminals WT, WT. . . Transmits the correction contents to the host computer HST.

Next, the contents of various assembly order files used in the assembly order management system 1 will be described. (1) AF assembly order file f2 First, the structure of the AF assembly order file f2 will be described with reference to the drawings. FIG. 5 is a diagram showing a record configuration of the AF assembly order file f2. The records shown in FIG. 5 are created for each vehicle lot. That is, the AF assembly order file f2 is a set of records having the configuration shown in FIG.

In FIG. 5, a search key 401 is data for searching this record, and an identification code 40
2, an AF line number 403, an AF-OFF date 404, and a rank number 405. Identification code 402
Is data that makes it possible to identify that this record is a component of the AF assembly order file f1, and the AF line number 403 is the AF line number AF1-1, 1-2 to AF4-1,
4-2 This is data indicating the production line number of the vehicle body corresponding to any of them. The AF-OFF date 404 is data indicating the date on which the vehicle lot corresponding to this record goes off-line from the AF line AFn.
Is data indicating the order number serially assigned to each record.

Further, in the record in the AF assembly order file f2, in addition to the search key 401, a lot number 406 assigned to the corresponding body lot, a body model code 40
7, the number of the vehicle body lots 408, the AF-OFF time 4
10, AF-ON date 411, AF-ON time 412,
Data such as an onboard engine model code 413, an AE line number 415 indicating the number of an AE line AEn in which an engine to be assembled to the vehicle body lot is produced, and the like are stored.

(2) AE Assembly Order File f3 Next, the structure of the AE assembly order file f3 will be described with reference to the drawings. FIG. 6 is a diagram showing a record configuration of the AE assembly order file f3. The records shown in FIG. 6 are created for each engine lot. That is, the AE assembly order file f3 is a set of records having the configuration shown in FIG.

In FIG. 6, a search key 601 is a data group for searching this record.
02, AE line number 603, AE-OFF date 60
4, the order number 605. Identification code 602
Is data that makes it possible to identify that this record is a record of the engine assembly order file f2.
The line number 603 is data indicating the production line number of the engine corresponding to each of the AE lines AE1 to AE4. The AF-OFF date 604 is data indicating the date when the engine lot corresponding to this record is line-off from the AE line AEn, and the order number 605 is data indicating the order number serially assigned to each record. is there

In the record in the AE assembly order file f3, in addition to the search key 601, the model code 607 of the engine, the number 608 of the engine lot, the AE
-OFF time 610, AE-ON date 611, AE-O
N time 612, search key 6 of AF assembly order file f2
13 items are stored.

(3) Calendar File f1 The calendar file f1 is composed of a plurality of records, like the files f2 and f3. In this record, an identification code that can identify that the record is a component of the calendar file f1, a division, a corresponding AF line or AE line number, and a calendar target year and month are stored as search keys. . Also,
The actual operation days (1st to 31st) of the calendar target year and month are stored. In the section classification, an identifier for identifying that the target of the record is any one of the AF lines AF1-1, 1-2 to AF4-1, 4-2 or the AE lines AE1 to AE4 is stored.

(4) Working hours master file f4
As in the case of f3, the record is composed of a plurality of records.
It stores work end time, break time, actual working time, and the like. The work divisions are provided with divisions such as "normal work", "two shifts", "normal overtime", and "other factory", and a work time master corresponding to the work division is stored.

(5) Work division file f5 The work division file f5 is composed of a plurality of records, like the files f1 to f4, and includes an identification code of this record, a division, a vehicle body production line number, and The year / month targeted by this data is used as a search key, and the work division for each actual working day in the target year / month is stored.

B: Operation of the Embodiment Hereinafter, the operation of the assembly order management system 1 having the above configuration will be described. First, when the power is turned on to the host computer HST and the work terminals WT, WT,.
A menu screen is displayed on the display of the work terminals WT. Then, the operator can sequentially execute the processing according to the input contents by selecting and inputting the work items displayed on the menu screen.

[0038]§1. Each file f for storing related information
Creation of 1, f4, f5 Here, each file is prepared as a preparation before making a production plan.
f1, f4, f5 creation and maintenance work
U. (1) From the menu screen, select “Work time master file f
If you select "4 Maintenance", the work master file
Work start / end time and break time according to work division in f4
Is stored. Also, from the following formula
The actual working time is determined and stored together. "Actual working hours" = "Work end time"-"Work start time"-
"Break time"

(2) If "work division file f5 maintenance" is selected from the menu screen, the work master file f is stored in the work division file f5 for each actual working day of the target year and month.
4 work divisions are registered. (3) Select “Create calendar file f1” from the menu screen, and select AF lines AF1-1, 1-2 to AF4-1, 4-2, and AE line AE1 in this automatic production line.
Register the actual working time for each line from AE4 to AE4. This registration is performed by assigning the work division to the actual working day. When there is a change in the work division registered in the work time master file f4 and information corresponding to the work division, it is necessary to input the change contents before creating the calendar file f1.

§2. Create AF assembly order file f2 Here, from the menu screen, select “AF assembly order file f2
When "Create" is selected and input, the host computer HST executes the processing shown in the flowchart of FIG. As a result, the assembling order management system 1 receives the AF assembling order information (see FIG. 1) created by the vehicle body assembling order system from the vehicle order and inputs the AF assembling order file f2.
Create

(1) Calculation of daily production volume, leveled production volume and tact per vehicle for each AF line First, when AF assembly rank information is input, step S3 is performed.
In step 01, the records in the AF assembly order file f2 are sorted in ascending order using the AF line number, the AF-OFF date, and the order number as sort keys. Then, a predetermined AF
-The vehicle lot number data of the same AF line number on the OFF date is sequentially read and added, and the AF line AF1-1
, 1-2 to AF4-1, 4-2.

After inputting the actual working hours of the relevant date from the work master file f4, the tact per vehicle per AF line, that is, the vehicle body 1 is calculated by the following formula.
Find the time required for production per vehicle. “Takt per vehicle” = “Actual working time” ÷ “Nissan number per AF line” The identification code 40 of the search key 401 of this record
2 is an identification code unique to the AF assembly order file f2, and the other key data 403 to 405 are contents corresponding to the search key 401 (AF line number 403, A
The F-OFF date 404 and the order number 405) are sequentially written. The details of the information written in each area other than the search key 401 will be described later.

(2) Calculation of AF-OFF Time Next, the process proceeds to step S302, where the assembly time required for one lot is calculated from the above-described tact time per unit, and the AF line AF is calculated.
AF-OFF for each lot of 1-1, 1-2 to AF4-1, 4-2
Calculate the time. Therefore, the required assembly time of the lot is calculated by the following formula. "Lot assembly time" = "Production volume per lot" x "Takt per vehicle"

If the required assembly time of a lot has a fraction of less than one minute, it is included in the required assembly time of the next lot, and the error in the time calculation is reduced to less than one minute per day. ing. Then, assuming the assembly start time of the lot as the assembly end time of the immediately preceding lot, the AF-OFF time of the corresponding lot is calculated by the following formula,
The data is written to the AF-OFF time area 410 of the record of the AF assembly order file f2. “Lot AF-OFF (assembly end) time” = “lot AF-ON (assembly start) time” + “lot assembly required time”

(3) Calculation of the number of units on the AF line Then, the process proceeds to step S303, and after the required assembly time is obtained, a time that is earlier than the AF-OFF time by the number of units on the AF line is set as the AF-ON time. A for each lot
Calculate the F-ON time. Then, the AF-ON date area 411 of the AF assembly order file f2 and the AF-O
Write to N time area 412.

(4) Other fields Further, the process proceeds to step S304, where the lot number 406,
Body model code 407, mounted engine model code 41
3, CCS code 414 and engine line number 4
The information corresponding to No. 15 is provided from the AF assembly order information and written into the AF assembly order file f2.

The records of the AF assembly order file f2 created as described above have different order numbers 405 and body model codes 407, respectively, and have different engine model codes 413 and AE line numbers 415. At this stage, the AE line is divided into lots of the AF line AFn.
Corresponding AEn, the body lot and engine lot are associated with each other.

(5) Creation of a car body assembly order list Here, the process proceeds to step S305, and as shown in FIG.
The records of the AF assembly order file f2 are edited for each AF line number 403 and output to a form. The records are AF line number 403, AF-OFF date 404, rank number 4
The output is performed in the ascending order using 05 as the sort key. In this figure, the same reference numerals are given to portions corresponding to each area of the AF assembly order file f2, and description thereof will be omitted.

§3. Maintenance Processing Here, by selecting the following items from the menu screen, the maintenance work of the AF assembly order file f2 can be performed. (1) Maintenance of Lots to be Added Next, if it becomes necessary to produce vehicles within a shorter time than usual due to the delivery deadline, the lot to be added and manufactured is registered in advance as an “addition lot”.

(2) KD Engine Production Plan Maintenance In some cases, engines (hereinafter referred to as KD engines) to be supplied to a remote assembly factory are produced on the AE lines AE1 to AE4 of the factory. When such a KD engine is mass-produced, the following AF line AF1-1,
Troubles such as a shortage of engines to supply 1-2 to AF4-1 and 4-2 occur. In order to prevent such a shortage of the engine and to promote the equalization of the production amount of each of the AE lines AE1 to AE4, the AE line AE1 having a small number of daily production is required.
Insert the KD lot into the production plan of AE4. here,
Only such registration of the “KD lot” is performed, and the process of actually inserting the KD lot into the production plan will be described later.

(3) Calculation of the number of preceding assemblies and maintenance of the number of preceding assemblies Next, the appropriate number of preceding assemblies is calculated. The method of calculating the number of preceding assemblies will be described later. Further, the calculated number of preceding assemblies is determined (manual input operation) to determine the number of preceding assemblies.

§4. When the user selects and inputs "Create AE assembly order file f3" from the AE assembly order file f3 creation processing menu screen, the host computer HST executes the processing shown in the flowchart of FIG. As a result, the assembly order management system 1 stores the calendar file f1 and the AF
An AE assembly order file f3 is created using the assembly order file f2 and the like as input.

(1) Initial Creation of AE Assembly Order Creation File f3 First, in step S201, an engine lot to be assembled on each AE line AEn is set from the above-mentioned AF assembly order file f2 and distributed to each AE line. In this distribution, each lot has an AF line
It is irrelevant to the time (order) used in AFn. For example, as shown in FIG. 3 and FIG. Thus, the AE assembly order file f3 is initially created. The “preceding assembly number” is the AF virtual line AFn
AE line, which is the source of the AE line, is set in units of AEn and on a daily basis. Here, the time that the engine is ahead of the vehicle body is limited to one hour or more and one day or less.

The above-mentioned "number of pre-assembled units" is manually calculated and input in advance, or a value obtained by automatic calculation according to the following formula is automatically set. "Number of pre-assembled units" = "Number of on-line units" + "Reference flow number" In the above formula, "Number of on-line units" refers to the number of units on each AE line AEn at a time. Is set. The “reference flow number” is the number of engines (the number corresponding to 2 hours) in which each AE line AEn precedes the 2-hour equivalent AF line AFn, or the minimum value of the preceding time of each engine (lot) is, for example, 1 hour. Is the number of engines assembled on the AE line AEn the day before.

The procedure for calculating the number of preceding assemblies will be described below. First, at the time when the AF line AFn ends the operation, “A
"2 hours equivalent number" is added to "the number on the F line AFn" to make an initial value. Then, the leading time for each lot for one week is calculated from the initial value, and the AE line having the shortest leading time (minimum leading time) is extracted. As a result, if the minimum preceding time is one hour or more, the initial value becomes the preceding number of assembled units as it is, and if it is less than one hour, the initial value is corrected as described below.

First, the number of engines that can be assembled in the time difference between the minimum preceding time and one hour is calculated by the following formula. "Number of units that can be assembled" = "Time difference" / "AE line AE"
Next, the AF line that is supplied with the engine in the minimum lead time
In AFn, "the number of units that can be assembled" is added to the number of preceding assemblies (initial value) of the corresponding AE line AEn. As a result, in each AE line AEn, the minimum preceding time does not become less than one hour.

(2) Calculation of the number of daily production units, the number of standardized units and the tact per vehicle for each AE line Next, in step S202, the AF assembly order file f
2 Same as at the time of creation, the daily production volume for each AE line AEn,
The leveled number and the tact per vehicle are calculated. A: Calculation of the daily production of engines First, the engines whose production is planned within one day are classified into the following categories, and the daily production is calculated.・ Engine models to be supplied to the following AF lines AF1-1 and 1-2 to AF4-1 and 4-2 ・ Engines included in the KD lot ・ Engines included in the added lot ・ Other engines And their daily production volume Is added for each AE line,
Calculate the daily production volume for each AE line.

B: Engine assembly for each of the AE lines AE1 to AE4
Rank Adjustment Next, the average number of daily production units during an arbitrary processing period (weekly or monthly) is calculated for each of the AE lines AE1 to AE4, and this is defined as "engine leveling unit". Therefore, among the AE lines AE1 to AE4, the AE line AE1
For AEAE4, by adding KD lots or additional lots to the production plan within the range not exceeding the engine leveling number, it is possible to establish an efficient engine assembly order.

Further, the tact per vehicle for each AE line, that is, the number of hours required for production per one engine is determined by the following formula. "Takt per vehicle" = "actual working time" / "number of Nissan vehicles by AE line" Then, the maximum number of vehicles per lot is calculated from the following formula. “Maximum number” = “1 hour” ÷ “Takt per unit” Here, the maximum number of units in one lot is set by a specific A
If engines of the same specifications are produced for a long time on the E line, the leading time tends to be short, and in order to avoid this, the maximum number of units corresponding to one hour is set here. Lots exceeding the maximum number are divided by the maximum number and divided into a plurality of lots, between which lots of other types are inserted. The number of the lots is stored in the number area 608.

(3) Rearrangement by AF-ON time or the like. Next, in step S203, the lots are rearranged in ascending order of the AF-ON time. At this time, the key is the AE line number 6 stored in the initial creation of (1).
03, date 604, rank number 605, AF-ON date 621, AF-ON time 622, AF-OFF date 61
6, AF-OFF time 620. Thus, each lot is rearranged in each AE line in an order required in a subsequent process (such as an AF line).

(4) Calculation of AE-OFF time. Next, in step S204, the AE-OFF time is calculated. The AE-OFF time is calculated by the following formula and stored in the AE-OFF time area 610. “AE-OFF time” = “AE-ON time” + “number of lots” × “tact per car” The AE-ON time described above indicates a work start time in a lot assembled first on the AE line.
The AE-OFF time is calculated in order from the first lot.
When the AE-OFF time overlaps with the rest time,
When a rest time is included between the E-ON time and the AE-OFF time, an exception process according to the rest start time and the rest time width is performed.

(5) Calculation of leading time and rank correction processing. Next, in step S205, AE-OFF of each lot is performed.
A time (preceding time) preceding the corresponding AF-ON time is calculated, and when the preceding time is less than the set minimum preceding time (one and a half hours) or becomes negative (missing). In step S206, the order of assembly is corrected. This correction is performed by processing such as lowering the order of the KD lot or the driven-in lot. And
In step S207, a lot number is assigned to each lot, and the process ends.

FIG. 4 shows the assembly order created through such a process. The assembly order shown in FIG.
It is set from the F assembly order through the process shown in FIG. 10 by the above-described processing. 3 and as shown in FIG. 10, the time t ₁ ~t each AF line AF1-1 until _2,
The engines assembled by 1-2 to AF4-1 and 4-2 will be produced on the AE lines AE1 to AE4 by the day before the engine is assembled. Therefore, the head of the engine of the B model to be assembled at the time t ₂ after the AF line AF1-1, sequentially AF line AF1-1, 1-2 ~AF4-1, the line AE3 from 4-2 to AE line AE3 Is scheduled. In other words, AF line AF1-1, 1-2 ~AF4-1, A between day assembled rank time t ₁ ~t ₃ 4-2 (indicated in D _1), B, C
AE line AE1 ~
On the day the assembly order of AE4 is mean that the model shown in D2 of the time t ₂ ~t ₄ are distributed, respectively.

At this stage, the AF lines AF1-1, 1-2 to
Since lots are sequentially sorted without considering the assembly time (AF-ON time) in AF4-1 and 4-2, for example, A
The E-line AE3 is assigned the C model after the B model. Then, A 'model to be assembled on the following day of the AF line AF1-1 (time t ₃ ~t ₄₎ is allocated to AE line AE3 followed after C model. Further, the models E, F, G, E 'of the AF line AF1-2 and the model T of the AF line AF3-1 are sequentially assigned to the AE line AE3. Then, on the AE lines AE1 and AE3 where the daily production volume is lower than the leveling volume,
KD lots are sorted.

In this manner, the assembly order shown in FIG. 10 is set. Next, the assembly order in FIG. 10 is corrected in consideration of the production times of the AF lines AF1-1 to AF4-2. The result is the assembly order shown in FIG. In this figure, the width occupied by each lot indicates the time required for assembling each lot. The lots are ranked in the AE lines AE1 to AE4 in consideration of the AF-ON time and the AF-OFF time, and each lot has a sufficient leading time.

The production order of the AE lines AE1 to AE4 is adjusted by comparing the assembling order of the AE lines AE1 to AE4 with the data such as the stock amount of the assembled engine. In the case of -1 to AF4-2, the shortage of engine supply due to the shortage of finished engine stock can be prevented, and the production efficiency can be improved.

As described above, according to this system, the production plan and the assembly order of the engine line conventionally determined manually according to various conditions to be adjusted are determined by the automatic calculation process. Therefore, it is possible to greatly reduce the time required for the determination. In addition, since the AE assembly order file f3 at any time (date, month, year unit) can be created based on the data of the AF assembly order file f2,
It is possible to easily cope with a change in the production mode, and to increase the production efficiency in that case. In this embodiment, an example is shown in which there are actually eight AF lines. However, the number of AF lines need not be eight, and each AE line may supply an engine to a virtual AF line. good.

[0068]

As described above, according to the present invention,
In the order creation means, when the production start time for each lot is earlier or the production start time is the same, the production order is assigned to the set in the upstream order file in the earlier production end time for each lot. This set includes a production start time and end time for each lot of a product using each part, a part specification of each part, and a lot set for production.
It is composed of the required time, and is created based on the set in the downstream order file having the production start time and end time for each lot of the product and the component specification of each component used for the product. Further, in order to create unit, the production start time and end time of each part stored in the set in accordance with the production order is calculated based on the plant essential time, production start time of each the end time and the lot Is calculated. In the order changing means, a lead time indicating how much the production end time of the parts used in each lot precedes the production start time of each lot is set in advance, and the difference is less than the lead time. If not, the production order is changed. Therefore, there is an effect that the production order can be adjusted efficiently while considering various judgment conditions including time and time.

[Brief description of the drawings]

FIG. 1 is a diagram showing a functional configuration of an assembly order management system 1 according to an embodiment of the present invention.

FIG. 2 is a block diagram showing a configuration of each assembly process according to the embodiment.

FIG. 3 is a diagram showing an assembly order of AF lines according to the embodiment.

FIG. 4 is a diagram showing an assembly order of AE lines according to the embodiment.

FIG. 5 is a diagram showing a file configuration of an AF assembly order file f2 according to the embodiment.

FIG. 6 is a diagram showing a file configuration of an AE assembly order file f3 according to the embodiment.

FIG. 7 is a flowchart showing a processing procedure of an AF assembly order creation routine according to the embodiment.

FIG. 8 is a form output example of an AF assembly order file f2 according to the embodiment.

FIG. 9 is a flowchart showing a procedure for creating an AE assembly order file f3 according to the embodiment.

FIG. 10 is a diagram showing an AE line assembly order (intermediate progress) according to the embodiment.

[Explanation of symbols]

HST: Host computer (preceding production number calculation means,
Order creating means, order changing means), WT, WT work terminal 1, engine assembly order system (production order management system) f1 calendar file (operating schedule file) f2 AF assembly order file (Downstream order file), f3... AE assembly order file (upstream order file), f4... Working time master file (working schedule file), f5... Working division file (working schedule file).

Continuation of the front page (72) Inventor Yukio Aizawa 1907, Hirata-cho, Suzuka-shi, Mie Honda Motor Co., Ltd. Suzuka Factory (56) References JP-A-5-158212 (JP, A) JP-A-4-107676 ( JP, A) JP-A-5-158946 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) G05B 19/418 B23Q 41/08

Claims (2)

(57) [Claims] 1. A production line having a downstream line for assembling products in lot units by using a plurality of types of parts continuously produced in lot units in an upstream line,
A production order management system that manages the order of production of the parts, comprising: a production start time and an end time for each lot of the product; a downstream order file storing part specifications of each part used in the product as a set; An upstream order file storing, as a set, a production start time and an end time for each lot of a product in which the parts are used, a part specification of each part, and a lot assembly time required for production; and production start for each lot. When the production start time is the same or the production start time is the same, the production order is assigned to the set in the upstream order file in the production end time for each lot in the earlier production end time. the stored production start time and end time of each component is calculated on the basis of the plant needed time, at the start of production of the respective lot and this end time A ranking creating means for calculating a difference between the production start time and the production start time of each lot. Means for changing the production order when the time is less than the preceding time, the operation day, production start time, and production end of each of the production lines.
Operating schedule consisting of time, rest start time and rest duration
Refer to the file and check the part
A preceding production number calculating means for calculating a row production number, wherein the ranking creating means includes a production start time and a production start time of the downstream line;
1st and 2nd which added the preceding time to the production end time
2 corresponding to the product assembled during the time of 2
The production of each lot is added to the set in the upstream ranking file.
Start time is earlier or the production start time is the same
In this case, the order of production is in ascending order of production end time for each lot.
A production order management system characterized by adding ranks. 2. During an arbitrary period in the upstream line
Of parts produced in excess of the average daily production
Previous in the set in the upstream ranking file corresponding to the
Create multiple sets by dividing the required time
Is replaced with the corresponding set and the upstream order file is replaced.
To be produced in excess of the average daily production
Dividing means for adjusting so as not to have a lot of each part, wherein the order creating means includes the upstream order including the plurality of sets;
Processing the set in the file.
Production order management system according to claim 1 that.