JPH07256532A - Integrated manufacturing control system - Google Patents

Abstract

PURPOSE:To carry out the delivery management for parts and assembly management, taking account of the state of an assembly line, as for an integrated manufacture management system for the efficient production even in case of small lot multi-production. CONSTITUTION:An integrated manufacture management system includes a manufacture management part 1, warehousing management part 2, assembly line management part 4, and an assembly line 3, and the manufacture management part 1 forms a delivery order for grooping-processing the manufacture order and delivers the result to the warehousing management part 2, and forms an assembly order sent out to the assembly line management part 4 through the grooping-processing taking account of the work-in-process quantity in the assembly line 3. The warehousing management part 2 delivers a part according to the delivery order and transfers the part to the assembly line 3, and the assembly line management part 4 controls the assembly line 3 according to the assembly order.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an integrated manufacturing control system which enables efficient manufacturing control even in the case of high-mix low-volume production. In mass production of the same product type, production efficiency is high and it is easy to reduce costs. However, in build-to-order manufacturing, it is often the case that high-mix low-volume production is performed, and it is difficult to increase production efficiency. Therefore, it is considered to use the grouping method even in the case of high-mix low-volume production. However, simply performing grouping does not always improve the production efficiency. Therefore, it is desired to improve the production efficiency even in the case of high-mix low-volume production.

[0002]

2. Description of the Related Art In a conventional manufacturing control system,
A manufacturing order is created corresponding to the product delivery date, etc., and a shipping order and an assembly order are formed according to the manufacturing order.
Parts are delivered from an automated warehouse or the like in accordance with a delivery order, and the delivered parts are conveyed to an assembly line. In this assembly line, parts are assembled according to the assembly order.

FIG. 32 is a schematic explanatory view of an example of an assembly line, showing a main part of the assembly line of a printed circuit board. The printed circuit board 200 before component mounting is stored in the storage shelf 204 with the storage of the printed circuit board 200 managed by the circuit board storage management unit 202. The components such as the semiconductor integrated circuit device and various electronic circuit components mounted on the printed circuit board 200 are different depending on the circuit scale and the like, but are, for example, about 20 to 50 types and about 100 to 300 per printed circuit board. It will be about individual pieces. Such parts are attached to a tape for each type, and the reel 201 around which the tape is wound is managed by the warehousing management unit 203, and an ID (identification information) corresponding to a manufacturing order or the like is given, and the ID label is printed. And is stored in the storage shelf 204.

The reel 201 and the cartridge 205 are taken out from the storage shelf 204, the ID of the reel 201 and the cartridge 205 are associated with each other in an associating unit 206, and are supplied to the automatic knitting apparatus 211. The cartridge 205 is mounted on the pallet 208 by the automatic knitting device 211. The printed circuit board 200 is an ID
It is supplied to the application device 210, is provided with an ID corresponding to the printed circuit board 200, is mounted on the rack 207 for each predetermined number of sheets, and is sequentially conveyed.

Next to the ID assigning device 210 and the automatic knitting device 211, the assembly line is a solder printer 212, an adhesive applicator 213, small component mounting machines 214 and 215, a variant component mounting machine 216, a reflow oven 217, and a cleaning machine. A machine 218, a curing furnace 219, appearance inspection devices 220 and 221, a manual correction unit 222, and the like are arranged and configured. Printed circuit board 2
00 or the rack 207 is transported by the self-propelled vehicle 209 or the like controlled by the transport control unit 223.

Therefore, in the printed circuit board 200, the solder printer 212 prints the cream solder on the portions to be soldered to the terminals of the component, and the adhesive applicator 213 mounts the component so that the adhesive does not move before reflow. Is applied, small parts such as standardized surface mount parts are mounted at predetermined positions on the printed circuit board 200 by the small part mounters 214 and 215, and the irregular shape part mounter 216 prints parts having nonstandard specifications. It is mounted at a predetermined position on the board 200 and heated in the reflow furnace 217 by infrared rays, a high temperature inert gas flow, or the like to carry out batch reflow soldering. Then, the washing machine 218 removes the paste and the like. Then, the curing furnace 219 performs drying and curing processing, and the appearance inspection devices 220 and 221 perform an inspection such as whether or not the components are normally mounted, and whether or not the soldering is normally performed, and the abnormality is detected. Manual correction section 22
It is modified by the worker in 2.

In assembling the printed circuit board as described above, when the scheduled delivery date of the manufacturing order comes, the inventory of the parts used according to the manufacturing order is reserved and the non-defective product is delivered. . In addition, when the delivered parts are put into the assembly line, the small part mounting machines 214, 21
The automatic mounting machines such as the No. 5 and the odd-shaped component mounting machine 216 are grouped so as to reduce the number of setups when mounting components on other types of printed circuit boards.

[0008]

When a component is mounted on a printed circuit board by mounting it on an automatic mounting machine, the component is attached to a tape, and the tape is supplied in a state wound on a reel 201. The reel 201 usually contains several thousands of parts. Therefore, if you need several tens of parts in one manufacturing order and several hundreds of the same parts in another manufacturing order on another delivery date, you need two manufacturing orders. In many cases, grouping cannot be done, and therefore two reels will be delivered. As a result, there is a problem that inventory on the site increases more than necessary.

Further, in the assembly line, grouping can be performed in consideration of the degree of similarity (commonality of parts) between drawing numbers so that the number of setups of the automatic mounting machine etc. can be minimized. When it is necessary to reduce the assembly order, or when there is a vacancy in the assembly line, the effect of grouping becomes low, or the time required for the grouping process becomes long and the assembly line is in a waiting state. There was a problem that occurs. Further, in the case of only assembling a small lot, there is a problem that the tact balance between the preparatory preparatory work for the assembly line and the assembly line is lost even if a plurality of assembly orders are grouped.

Further, as a grouping means of the conventional example, a reference drawing number (the smallest drawing number of the used parts type) is sequentially rounded to a drawing number having the smallest number of parts different from the parts used in the drawing number. Proposed is a method of determining one group immediately before the number of channels (the number of cartridges 205 that can be mounted) of the automatic loading machine is exceeded, or a method of selecting a combination that minimizes the number of groups in all combinations of drawing numbers. Has been done.
However, according to the former method, since the number of unmatched parts is calculated each time the drawing number is rounded, the time required to compare the parts becomes long, and there is the problem that setup efficiency that occurs between groups cannot be improved. In addition, there is a problem that the grouping efficiency (how many drawing numbers are included in one group) is not always improved. Further, according to the latter means, in order to perform the optimum grouping, the number of times corresponding to the number of the drawing numbers is always calculated and the one having the highest grouping efficiency is selected, but for that purpose, enormous amount is required. There is a drawback that it is not practical because it requires processing time. The present invention is
The objective is to enable optimal grouping in consideration of the condition of the assembly line and to improve production efficiency.

[0011]

An integrated manufacturing control system of the present invention will be described with reference to FIG. 1. (1) A manufacturing control section 1 for creating a shipping order and an assembly order according to a manufacturing order, and a shipping order according to a shipping order. A warehouse management unit 2 for delivering parts, an assembly line 3 for supplying the components delivered from the warehouse management unit 2 for assembly work, and an assembly line management unit 4 for controlling this assembly line according to an assembly order. In the integrated manufacturing control system, the manufacturing control section 1
A manufacturing order is grouped to form a delivery order, and a grouping process is performed based on the manufacturing order and the state of the assembly line 3 to form an assembly order.

(2) Further, the manufacturing control unit 1 determines the shipping processing target period based on the manufacturing order and the in-process quantity indicating the state of the assembly line 3, and forms the shipping order.

(3) Further, the manufacturing management section 1 selects a grouping condition for rounding and shipping based on the manufacturing order and the in-process quantity indicating the state of the assembly line 3 to form a shipping order.

(4) Further, the manufacturing control section 1 is provided with a process selection file in which the grouping conditions are stored, and the grouping conditions stored in the process selection file can be updated based on the increase / decrease judgment of the work-in-process quantity of the assembly line 3. it can.

(5) Further, the manufacturing control unit 1 cuts out the assembly order from the manufacturing order file, and manages the assembly order in which the order of loading is determined based on the grouping conditions from the process selection file and the in-process quantity of the assembly line 3. It is sent to the section 4.

(6) Further, in the manufacturing control section 1 or the assembly line management section 4, based on the progress status of the in-process rack of the assembly line 3 and the standard man-hours for each drawing number and process according to the manufacturing order, The rack completion time is calculated, the urgency is calculated from the magnitude relation between the completion time and the preparation time for the assembly line 3, grouping processing is performed according to this urgency, and an assembly command is sent to the assembly line 3. .

(7) Further, the assembly line management unit 4 obtains the similarity between the drawing numbers by the assembly order, determines the order of loading in the order of high similarity, and determines the order of loading for performing the grouping processing according to this order of loading. It has a processing unit.

(8) Further, the throwing order determination processing unit determines the similarity as
It is determined by the angle or difference between the vectors with the value indicating the use or non-use of the component type corresponding to the drawing number as an element.

(9) Further, the throwing order determination processing unit weights the value indicating the use or non-use of the component type according to the occupied pitch of the component type, and the angle between the vectors having the weighted value as an element. Alternatively, the similarity between the drawing numbers can be obtained from the difference.

(10) Further, the input order determination processing section is provided with a similarity table in which the similarity between the drawing numbers is expressed by a matrix,
It is possible to perform rearrangement in the descending order of similarity in the similarity table, and perform the order of insertion and grouping processing in the order of the rearranged similarity.

[0021]

[Action]

(1) The manufacturing control department 1 is responsible for the delivery date, quantity, and
Grouping processing is performed based on the product type and the like to form a delivery order and the delivery order is sent to the warehouse management unit 2. The warehouse management unit 2 issues the parts in accordance with the delivery order. Further, the manufacturing management unit 1 performs a grouping process based on the manufacturing order and the state of the assembly line 3 to form an assembly order, and sends it to the assembly line management unit 4. The assembly line management unit 4 controls the assembly line 3 according to the assembly order. That is, the grouping conditions and the like are changed according to the state of the assembly line 3 to form an assembly order so that waiting for the assembly line 3 and an increase in parts inventory do not occur.

(2) The state of the assembly line 3 can be represented by the size of the work in process. That is, when there is a vacant time in the assembly line 3, the number of work-in-process is zero, and when the number of work-in-process is large, the correspondence between the delivery order and the assembly order cannot be efficiently engaged. Therefore, the shipping order is grouped based on such an in-process quantity.

(3) Further, the manufacturing control section 1 selects a rounding unit such as a manufacturing number or a drawing number on the basis of the manufacturing order and the quantity in process on the assembly line 3, and the assembly line 3 is selected. Create an issue order so that the number of work in process does not increase, and the warehouse management department 2
Send to.

(4) Further, the manufacturing control section 1 determines whether the quantity of work in progress on the assembly line 3 is increased or decreased. If the quantity of work in progress significantly increases due to the grouping process, it is judged that the grouping conditions are not appropriate, Update the grouping condition. Thereby, the grouping conditions can be automatically optimized.

(5) Further, the manufacturing control section 1 cuts out the manufacturing order from the manufacturing order file based on the delivery date, the planned assembly date, etc., and determines the order of inputting the assembly order based on the grouping condition and the quantity in process. Assembly line management department 4
Send to.

(6) Further, the completion time of the in-process rack is obtained based on the progress status of the in-process rack on the assembly line 3 and the standard man-hours for each drawing number and process according to the manufacturing order. The rack in this case is transported between various automatic machines arranged in the assembly line 3, and accommodates a printed circuit board and the like. After the completion time of this work-in-process rack is obtained by simulation, the degree of urgency is obtained from the magnitude relationship with the time of preparation for loading on the assembly line 3. That is, the presence or absence of a margin time, the necessity of shortening the knitting processing time, and the like are known, and therefore the grouping processing is performed according to this urgency. As a result, the assembly line 3
It is possible to manage so that there is no waiting time in the field.

(7) Further, the loading order determination processing section of the assembly line management section 4 obtains the degree of similarity between drawing numbers according to the assembly order from the manufacturing management section 1. Then, the order of loading is determined in descending order of similarity, and grouping processing is performed based on the configuration, operating state, etc. of the assembly line 3.

(8) Further, the placement order determination processing unit sets a value indicating use or non-use of the component type corresponding to the drawing number, for example, "1" for use and "0" for non-use, and these are used as elements. A vector corresponding to the drawing number is formed, and the similarity between the drawing numbers is obtained from the angle or the vector difference between the vectors. In this case, the degree of similarity due to the angle between the vectors corresponds to the number of coincidences of the component types between the drawing numbers, and thus the larger the value, the higher the degree of similarity. Further, the similarity due to the vector difference corresponds to the number of disagreements of the component types between the drawing numbers, and thus the smaller the value, the higher the similarity.

(9) The parts are not all the same size,
There are parts with wide widths. Such parts occupy multiple channels of the pallet for the automatic loader. Therefore, assuming this as the occupied pitch, the value indicating the use or non-use of the component type is weighted by the occupied pitch. For example, the larger the occupied pitch, the greater the weighting. Then, a vector corresponding to the drawing number having the weighted value as an element is formed, and the similarity between the drawing numbers is obtained from the angle between the vectors or the vector difference.

(10) Further, a similarity table in which the similarity between drawing numbers is expressed by a matrix is provided. By rearranging the similarity table in descending order of similarity, grouping can be performed from an arbitrary position by a number corresponding to the number of channels of the automatic mounting machine. In that case, the similarity between the drawing numbers in each group is high, and the number of setup changes can be reduced.

[0031]

EXAMPLE FIG. 2 is an explanatory view of an example of the present invention.
Is a manufacturing management system, 12 is a warehouse management system, 13 is an assembly line management system, 14 is a manufacturing order file,
15 is a parts table data file, 16 is a processing selection file for grouping processing, 17 is an in-process order file,
18 is a delivery order file, 19 is an assembly order file, 20 is an assembly result file, 21 is a mounting data file, 22 is a process selection file for component grouping processing, 23 is a rack management file, 24 is a pallet management file, Reference numeral 25 is a group management file, 26 is a mounting data file, and 27 is an assembly line.

The manufacturing management system 11 follows the manufacturing order from the manufacturing order file 14 and the parts table data from the parts table data file 15 and the process selection file 16
A delivery order and an assembly order are formed on the basis of the data indicating the condition of the grouping process from the work order data, the work in progress data from the work in process order file 17, and the assembly record data indicating the state of the assembly line 27 from the assembly record file 20. Then, a delivery order is added to the warehouse management system 12 via the delivery order file 18, and an assembly order is added to the assembly line management system 13 via the assembly order file 19.

The assembly line 27 can have the structure shown in FIG. 32, for example, and the assembly line management system 13 includes a rack management file 23, a pallet management file 24, a group management file 25, and a mounting data file. By controlling 26, the printed circuit board and the components put into the assembly line 27 are mounted and soldered on the printed circuit board by a solder printer, an automatic mounting machine or the like, and an inspection is performed to complete the product. In that case, the printed circuit boards are housed in a rack every predetermined number and managed based on the rack management file 23. Various parts are made into reels, the reels are attached to the cartridges, and the pallet to which a required number of cartridges corresponding to different types of parts are attached is managed based on the pallet management file 24.
Then, according to the mounting data from the mounting data file 26, the component is mounted on the predetermined position of the printed board by the automatic mounting machine.

The manufacturing management system 11, the warehouse management system 12, and the assembly line management system 13 described above can be realized by separate processors or arithmetic processing functions of a single processor.

FIG. 3 is an explanatory diagram of a manufacturing order, a shipping order, and an assembly order. The manufacturing order of the manufacturing order file 14 includes, for example, a manufacturing number, a drawing number, a command number, and a scheduled date. It includes the scheduled date, the scheduled assembly date, the scheduled test date, and so on. The delivery order of the delivery order file 18 includes, for example, the delivery order, the delivery group number, the manufacturing number, the drawing number,
The number of commands, the scheduled delivery date, the date of delivery, etc. are included, and the assembly order of the assembly order file 19 includes, for example, the serial number, the drawing number, the number of commands, the scheduled date of assembly, and the like.

The manufacturing management system 11 uses the manufacturing order from the manufacturing order file 14 to select the process selection file 1
Outgoing order determination processing is performed based on the grouping conditions etc. from 6 and the resulting outgoing order is issued by the outgoing order file 1
Store in 8. Also, an assembly order is formed by the assembly order cutout process and stored in the assembly order file 19. With respect to the assembly order of the assembly order file 19, a placement order determination process is performed based on the grouping conditions and the like from the process selection file 22, and thereby a placement order table 28 is formed. This throwing order data includes, for example, a throwing order, a throwing group, a manufacturing number, a drawing number, and a command number.

FIG. 4 is an explanatory diagram of the in-process order, the parts table data, and the process selection. The in-process order file 1 in FIG.
7, parts table data file 15 and processing selection file 16
An example is shown below. The work-in-order file 17 is configured to include processes, manufacturing numbers, drawing numbers, command numbers, planned delivery times, completed numbers, work-in-process numbers, group numbers, and the like, and the parts table data file 1
5 is a configuration including drawing numbers, parts specifications, quantities, and the like. Further, the process selection file 16 includes the in-process quantity, the target order period, the grouping conditions, etc. When the in-process quantity is small, the grouping processing is performed in the unit of drawing number, and when the in-process quantity is large, the grouping processing by the priority of the parts commonality is performed. Indicates to do.

FIG. 5 is a flow chart of the shipping order determination processing, and the manufacturing management system 11 activates the function of the shipping order determination processing in order to send the shipping order to the warehouse management system 12. By this issuing order determination processing, the current in-process quantity is calculated based on the in-process number from the in-process order file 17 (a1). For example, in the case of the contents of the in-process order file 17 shown in FIG. 4, the current in-process quantity becomes 1300 by adding the in-process number.

Next, the delivery target order cutout period is determined with reference to the grouping conditions of the process selection file 16 (a2). Then, the number of work in process and the reference value are compared (a
3) If the number of work in process is larger than the reference value, grouping according to the degree of commonality of parts (a4), if the number of work in progress and the reference value are almost the same, grouping by production number (a5), the number of work in progress is the reference value If the number is smaller, the grouping process is determined as in the case of drawing-out by unit (a6), and a shipping order is created (a7). As mentioned above, the current work-in-process quantity is 13
In the case of 00 sheets, referring to the contents of the process selection file 16 in FIG. 4, the target order period is 7 days, and the grouping condition has the component commonality priority. In order to create a delivery order, the production order file to be assembled is read from the production order file 14 n days after the present (7 days after the target order period in the case of the above-mentioned work-in-process quantity of 1300 sheets), and grouping processing is performed according to the degree of commonality of parts. And stores it in the delivery order file 18. The delivery order is sent from the delivery order file 18 to the warehouse management system 12.

FIG. 6 is an explanatory diagram of the grouping process.
The in-process increase / decrease determination process (b1) is performed by the manufacturing order file 14
The increase or decrease of work in progress is determined based on the manufacturing order from the work order and the number of work in progress from the work order file 17, and the assembly result from the assembly line management system 13 via the assembly result file 20, and based on the assembly result from the assembly result file 20. The number of work in process in the work in process order file 17 is updated.

The in-process increase / decrease data by the in-process increase / decrease determination process (b1) is stored in the in-process increase / decrease file 29, and the grouping condition of the process selection file 16 is updated by the grouping process selection file maintenance process (b2). That is, when the grouping process is performed according to the grouping conditions of the process selection file 16 and the in-process quantity significantly increases, it is not the optimum grouping condition and is updated.

FIG. 7 is an explanatory diagram of grouping.
(A) shows an example of product number priority grouping, where the product number S1 is group 1, the product number S2 is group 2, and the product number S3 is group 3, and the group 1 is n hours after the present.
Indicates that assembly is started, group 2 is started to be assembled thereafter, and group 3 is to be started after (n + m) hours from the present.

Further, (B) shows an example of component commonality priority grouping, which is the same drawing number Z1 in the product numbers S1 and S2.
The case where the same drawing number Z2 in the manufacturing numbers S1 and S4 and the drawing number Z3 in the manufacturing numbers S1 are group 1 and the other are group 2 is shown. Then, it indicates that assembly of the serial number S1 is started n hours after the present, assembly of the serial number S2 is started after that, and assembly of the serial number S4 is started (n + m ') hours after the present.

FIG. 8 is an explanatory view of the input order determination and the grouping processing. The same reference numerals as those in FIG.
Is a pallet organization system, 32 is a reel management file,
33 is a parts master file, 34 is a process selection table,
Reference numeral 35 is an input order determination processing unit, 36 is a grouping processing unit,
37 is a mounting data creation unit, 38 is a rack progress table,
Reference numeral 39 is a man-hour management file.

The placement order determination processing unit 35, the assembly order from the assembly order file 19 and the mounting data file 21.
The loading order is determined based on the mounting data from No. 3, the selection condition from the process selection table 34, and the rack progress from the rack progress table 38. The grouping processing unit 36 performs grouping processing based on the mounting data from the mounting data file 21, the reel management data from the reel management file 32, the component data from the component master file 33, and the placement order data, and group information. Is stored in the palette management file 24 while being added to the mounting data creation unit 37.

The mounting data creating unit 37 includes the mounting data from the mounting data file 21 and the grouping processing unit 36.
Based on the group information from, the mounting data including the component type to be mounted on the printed circuit board and its mounting position is created and stored in the mounting data file 26, and the man-hour management file 3
The man-hour corresponding to the mounting data is stored in 9. A command based on the group information is added from the pallet management file 24 to the assembly line 27, and the rack management file 23 is also added.
From the rack management data, the progress information of the rack is added to the rack progress table 38 via the rack management file 23. Further, mounting data is added to the assembly line 27 from the mounting data file 26, and the automatic mounting machine arranged on the assembly line 27 is controlled based on this mounting data.

FIG. 9 is a diagram for explaining the creation of the rack progress table. In the rack management file 23, as the rack ID,
The current position in the assembly line 27 corresponding to A, B, C, D, E, the manufacturing number, the drawing number, and the number of sheets are stored. Further, the man-hour management file 39 stores man-hours for soldering, mounting of small-sized components, mounting of odd-shaped components, etc. corresponding to the drawing numbers. The rack progress table 38 stores, for example, states and man-hours of a solder printing machine, a small-sized mounting machine, and an odd-shaped mounting machine in correspondence with the rack ID. For example, with respect to a printed circuit board accommodated in a rack A (rack whose rack ID is A), a solder printer has a process completion state of 10 man-hours, a small mounting machine has 30 man-hours in process, and a odd-shaped mounting machine has 25 man-hours. The previous state is shown.

FIG. 10 is an explanatory diagram of the in-process rack completion time. With respect to the knitting apparatus, the solder printing machine, and the small-sized mounting machine, at the current time, the rack A (rack with the rack ID A) is
The process in the small mounting machine is completed, and the rack B shows the state before the process in the small mounting machine after the process in the solder printing machine is completed. The racks C, D, and E are in the state before the process in the solder printing machine, and thus the racks C, D, and E are in the state before the process in the small mounting machine.

The maximum processing time is the maximum processing time for creating the knitting data to be given to the knitting device, and the maximum knitting time is the time required to mount the cartridges on all usable pallets. If the number of parts is small, the number of cartridges to be mounted on the pallet is small and the knitting time can be shortened. The printing time is the time required for cream solder printing on a printed circuit board in a solder printer. The time limit is the time obtained by subtracting the required process time and the current time in the solder printer of the previous process from the in-process rack completion time.

When the loading sequence determination process is started, a rack management file 23 for managing the progress of the rack, which is a unit of transport of printed circuit boards in the assembly line 27, and a man-hour required for each drawing number and process are managed. Tact management file 39
Then, the rack progress table 38 is created, the contents of the rack progress table 38 are read, and the current assembly line 2
The time when the final rack in process 7 completes the process on the small-sized machine is simulated to determine the time when the in-process rack completes. As a result, if the newly loaded rack arrives at the small-sized mounting machine before this completion time, the small-sized mounting machine does not have to wait.

FIG. 11 is an explanatory diagram of the processing based on the urgency level determination. The urgency levels 1 to 4 are determined based on the above-mentioned time limit, maximum organization time, and maximum processing time. Urgency 1 is the case where the time limit is less than the maximum formation time, the time has passed from the state in FIG. 10, and the rack E is in the state before the process in the small-sized mounting machine and waits after the rack E. It is necessary to shorten the knitting time so that the time does not occur. Since the knitting time tends to become longer as the number of types of parts increases, the grouping process is not performed and the order with the minimum number of types of parts is selected. Thereby, the knitting time can be shortened.

The urgency level 2 is defined as the relation of maximum organization time <limit time <maximum organization time + maximum processing time. In this case, assuming that the racks D and E are in a state before the process in the solder printing machine and the small-sized mounting machine, the maximum knitting time is considered to be secured because it is within the time limit, and the maximum processing time is Shorten the processing so that it is within the time limit. In that case, the processing time becomes longer as the number of groupings increases, so that the grouping processing is not performed. Also, in order to give a margin to the next knitting, it is preferable to select an order with a large lot number.

The degree of urgency 3 is defined as the relationship of time limit ≧ maximum processing time + maximum organization time. In this case, since the maximum processing time and the maximum organization time can be secured, the grouping processing that combines the orders of large and small lot numbers is performed to secure the takt time.

Further, the time limit >> maximum processing time + maximum organization time is set as urgency level 4. In this case, since the margin time is large, those having a high degree of commonality of parts are grouped. Thereby, the formation efficiency is improved. Further, as the grouping condition, the delivery date can be further considered. That is,
If the delivery date is imminent, it can be put into the assembly line 27 without performing grouping, and if the delivery date is late, the grouping range can be widened to improve the grouping efficiency.

FIG. 12 is an explanatory diagram of the process selection table. When the urgency levels 1 to 4 are set as described above, the number of component types, the tact time (the number of lots), the similarity (commonality), and the presence or absence of grouping. In the case of the urgency level 1, for example, the knitting time needs to be shortened, so the component type is determined with the highest priority and the grouping process is not performed. Further, in the case of the urgent level 4, the similarity (commonality) is determined with the highest priority, and the grouping processing is assumed to be present.

FIG. 13 is a flow chart for determining the order of loading. The in-process rack completion time is obtained by referring to the rack progress table 38 (c1). Then, the urgency levels 1 to 4 described with reference to FIG. 11 are obtained (c2). Then, the urgency level determination is performed by referring to the process selection table 34 (c3). When the urgency is 1, the order with the smallest number of parts and the large number of lots is selected (c4). When the urgency is 2, the order with the largest number of lots and the smallest number of parts is selected (c5). In the case of the urgency level 3, the order is rearranged in the order of the number of lots and selected in descending order (c6). In case of urgency 4,
The drawing numbers are rearranged in descending order of similarity, and orders are selected in that order (c7). Grouping processing is performed according to such selection (c8).

FIG. 14 is an explanatory diagram of prioritizing according to the degree of urgency. When the order management table stores orders 1 to 7, drawing numbers A to G, the number of commands and the number of parts,
In case of urgency 1, there is no grouping, and the one with the smallest number of parts and the large number of lots is selected.
Is selected. When the urgency is 2, the order 7 having the largest number of lots and the smallest number of parts is selected.

When the urgency is 3, the orders are rearranged in descending order of the number of lots. Therefore, the orders 7, 4, 1, 3, 6,
The priority order is 2, 5 and the grouping process is performed according to this priority order. If the urgency is 4, the drawing numbers are rearranged in descending order of similarity, so orders 5, 7, 1,
The priority order is 3, 6, 2, and 4, and the grouping process is performed according to this priority order.

FIG. 15 is an explanatory view of the loading order determination processing based on the degree of commonality of parts, 21 is a mounting data file, 26 is a loading data file, 28 is a loading order table, 35 is a loading order determination processing section, and 41 is loading data. A creation processing unit, 42 is a component channel setting processing unit, 43 is a component setup change table, 44 is a similarity table, 45 is a component use table,
Reference numeral 46 is a loading order determination processing unit.

FIG. 16 is a diagram for explaining the mounting data file creation. The assembly order file 19 to the drawing numbers Z1, Z2 ,.
.. The corresponding mounting data file 21 is created, and the mounting data file 26 is created based on the loading order table 28 and the part setup change table 43. The assembly order file 19 shows a case where grouping processing is performed in the unit of drawing number, and the mounting data file 21 includes a part symbol, a part specification,
It has a configuration including component mounting coordinates (X, Y, θ) and the like.
Further, the throwing order table 28 shows the same case as the throwing order table 28 in FIG.

The input sequence determination processing unit 35 in FIG.
According to the assembly order, the component use table 45 is created based on the mounting data from the mounting data file 21 having the content as shown in FIG. 16, and the placement order determination processing unit 46 refers to the similarity table 44 to determine the placement order. Then, the input order table 28 as shown in FIG. 16 is created. Also, the component channel setting processing unit 42 creates a component setup change table 43 as shown in FIG. 16 based on the component use table 45, and stores the data of the component setup change table 43 and the mounting data of the mounting data file 21. Based on this, the mounting data creation processing unit 41 creates the mounting data and stores it in the mounting data file 26. This onboard data file 26
16, the mounting data includes, for example, the component type number, the mounting position coordinates (X, Y), and the mounting angle (R).

FIG. 17 is an explanatory view of another process for determining the order of placement based on the degree of commonality of parts, 19 is an assembly order file, and 21 is
Is a mounting data file, 23 is a rack management file, 2
4 is a pallet management file, 25 is a group management file, 26 is a loading data file, 28 is a loading order table, 41 is a loading data creation processing unit, 43 is a parts setup change table, 51 is a loading order / group determination processing unit, 52
Is a parts use table, 53 is a placement order determination processing unit, 54
Is a similarity table, 55 is a grouping processing unit, and 56 is an equipment condition table.

The placement order / group determination processing unit 51 creates the parts use table 52 based on the mounting data from the mounting data file 21 according to the assembly order from the assembly order file 19, and the loading order determination processing unit 53. Determines the input order by referring to the similarity table 54 and creates the input order table 28. The grouping processing unit 55
Grouping processing is performed based on the parts usage table 52, the loading order table 28, and the assembly line equipment conditions in the equipment condition table 56, and the grouping processing results are displayed in the rack management file 23, the group management file 25, and the parts setup change table 43. Notice. Onboard data creation processing unit 41
Creates mounting data based on the mounting data from the mounting data file 21 and the component setup change data from the component setup change table 43.
In addition, the pallet management data of the pallet management file 24 is stored according to the contents of the part setup change table 43.

FIG. 18 is an explanatory diagram of a vector expression by the use and non-use of parts. The drawing numbers Z1, Z2, Z3, ...
, And parts a, b, c, ... Corresponding, “1” for the part used in correspondence with the drawing number, “0” for the part not used, and a vector expression consisting of elements of the number of parts. Indicates the drawing number. For example, the drawing number Z1 is (1, 0, 0,
1,0,1,0,0,1,1), and the drawing number Z6 is
(1,0,0,1,1,1,0,0,1,1).

FIG. 19 is a diagram for explaining the definition of similarity between drawing numbers. The angle θ between vectors is determined, and the smaller the angle θ, the greater the similarity. Since square root processing is included in this vector calculation, both sides are squared and the similarity is calculated as cos ²
It is represented by θ. That is, in the case of drawing numbers A and B, the degree of similarity = (the number of types of parts that match between drawing number A and drawing number B) ² /
The degree of similarity is calculated as (the number of component types of drawing number A × the number of component types of drawing number B). Therefore, the vectors A, B, C,
When D and E are shown in (A) and (B) of FIG. 19, the similarity to the vector A is B, C, D, and E in this order, and the similarity to the vector E is A, B, D, and The order is C.

FIG. 20 is an explanatory diagram of the parts usage table and the similarity table. The parts usage table of FIG. 20A shows the usage and non-use of the parts for the drawing numbers Z1 to Z6 and the parts a to i. When a similarity table is created using this parts usage table, the contents shown in (B) are obtained. In addition, for convenience, the case where the similarity between the drawing numbers that has no meaning is set to -1 is shown. For example, regarding the drawing numbers Z1 and Z6, the number of parts in the drawing number Z1 is 5, the number of parts in the drawing number Z6 is 6, and the number of matching parts is 5, so the similarity is 5 ^2. /(5×6)=0.833. Since the number of coincidences of the component types between the drawing numbers Z1 and Z5 is zero, the degree of similarity is 0.

21, FIG. 22 and FIG. 23 are explanatory views of the input order determination processing using the similarity table, showing the case of using the similarity table of FIG.
Is omitted. Further, h and i do not show the above-mentioned parts but show h = 1, 2, 3, ... And i = 1, 2, 3 ,. First, in step 1, in order to find the first drawing number candidate, the similarity table is searched to find the two drawing numbers with the lowest similarity. In this case, the drawing numbers 1 and 5 having a similarity of 0 are candidates.

In the next step 2, the first drawing number candidate drawing numbers 1 and 5 are selected, including one having the highest degree of similarity. In this case, the similarity between the drawing numbers 1 and 6 is 0.
Since 833 is higher than 0.450 which is the similarity between drawing numbers 5 and 4, drawing number 1 is selected as the first drawing number.

In the next step 3, the first drawing number 1
All rows (i = 1) are set to -1 so that they will not be selected in the subsequent processing. Then, the drawing number having the highest degree of similarity to the first drawing number 1 is selected. In this case, the drawing number 6 is selected.

In the next step 4 (see FIG. 22), all the selected rows (i = 6) of the drawing number 6 are set to -1, and the one having the highest similarity to the drawing number 6 is selected. .
In this case, the drawing number 2 is selected.

In the same manner, those having a high degree of similarity are sequentially selected, and the corresponding row of the selected drawing number is set to -1 so as not to be selected in the next selection process. Further, in the next step 5, when there are a plurality of drawing numbers having the same similarity to the drawing number 2, the similarity between the drawing number and the drawing number selected immediately before is checked and Select. Even in that case, if the similarities are the same, the similarity with the previously selected drawing number is checked and selected. For example, when the similarity is 0.250 with respect to the drawing number 2 and the same drawing numbers 3 and 5 exist, the similarity between the drawing number 6 selected immediately before and the drawing numbers 3 and 5 is compared. . Since the similarity in this case is 0.042, which is the same case, the similarity between the previously selected figure number 1 and figure numbers 3 and 5 is compared. In this case, the degree of similarity is higher in the case of the drawing number 3, so that the drawing number 3 is selected.

In the next step 6, the drawing number 5 having a high degree of similarity to the drawing number 3 is selected based on the above-mentioned method, and in the next step 7 (see FIG. 23),
The drawing number 4 having a high degree of similarity to the drawing number 5 is selected. By the above-mentioned processing, the content of the similarity table becomes -1 in all rows as shown in step 8 of, and the input order is
It is determined as 1 → 6 → 2 → 3 → 5 → 4.

FIG. 24 is an explanatory diagram of the similarity definition between drawing numbers based on the vector difference, and the similarity between drawing numbers is calculated by using the vector expression by using and not using the parts corresponding to the drawing numbers described in FIG. The case of expressing by vector difference is shown, and the number of dissimilar component types between drawing numbers is shown. Therefore, the similarity is highest when the value of the similarity is 0, and the larger the value is, the lower the similarity is. Therefore, FIG. 18 or FIG.
The similarity table when using the parts usage table of
It becomes what is shown in the lower part of FIG. In addition, the degree of similarity between drawing numbers, which is meaningless in the combination, is set to -1.

25, 26, and 27 are explanatory views of the input order determination processing using the similarity table, and show the case where the similarity table shown in FIG. 24 is used. In step 1 of 1., in order to find the first drawing number candidate, the drawing number having the lowest similarity between the drawing numbers is searched. In this case, figure numbers 1 and 5 with a similarity of 9 are found.

In the next step 2, the drawing numbers including the ones having a high degree of similarity are found among the drawing numbers 1 and 5 of the head candidates. In this case, the drawing number 1 including the drawing number 6 with the similarity 1 is selected as the top drawing number. All the rows (i = 1) of this figure number 1 are -1. In the next step 3, the drawing number 6 having the highest similarity to the drawing number 1 is selected.

In the next step 4 (see FIG. 26), all the rows (i = 6) of the drawing number 6 are set to -1, and the drawing number having the highest similarity to the drawing number 2 is found. In this case, as shown in the next step 5, when a drawing number with the same similarity is found, the similarity with respect to the drawing number selected immediately before is compared, and in that case also, the similarity is the same. Further, the degree of similarity to the previously selected drawing number is compared. By such processing, the drawing number 3 is selected in step 5 of FIG.

In the next step 6, the row (i = 3) of drawing number 3 is set to -1, and the drawing number having the highest similarity to drawing number 3 is found. In this case, the drawing number 5 is selected. In the next step 7, the line (i = 5) in FIG.
Then, the drawing number having the highest similarity to the drawing number 5 is found. In this case, the remaining figure number 4 is selected. And
In step 8 of FIG. 4, the row (i = 4) in FIG. 4 is set to -1, and the input order is determined to be 1 → 6 → 2 → 3 → 5 → 4.

FIG. 28 is an explanatory diagram of rearrangement based on the degree of similarity. The part use table before rearrangement is used and the drawing numbers Z1 and Z are used.
2, Z3, ... In the order of loading, for example, the parts a, d, f, i, j are attached to the drawing number Z1, and the parts a, d, i, j are removed for the drawing number Z2. , Parts b, c, e are to be attached. Therefore, the sum of the number of times of attachment and removal of the components a, b, c, ... J from the knitting device on the assembly line is 32.

On the other hand, when the parts use tables are rearranged based on the above-mentioned similarities, the input order becomes the drawing numbers Z1, Z6, Z2, Z3, Z5, Z4.
Attach parts a, d, f, i, j for drawing number Z1,
Part number e6 is not removed, only part e is attached. Therefore, the parts a, b, c, ... J
The total number of attachments and removals was 23 times. That is, the rearrangement reduces the number of times the parts are attached and removed, and the knitting time can be shortened.

FIG. 29 is a flow chart of the input order determination processing. As described above, a vector expression is used corresponding to the drawing number,
The angle between two drawing numbers is calculated, and the similarity tables 44 and 54
(See FIGS. 15 and 17) is created (d1). Next, it is determined whether or not all the drawing number combinations have been processed (d2),
When the calculation of the similarity is completed, the two drawing numbers of the combination having the lowest similarity are set as the first drawing number candidate (d3), the drawing number having the highest similarity to the first drawing number candidate is found, and the similarities are compared. , The one with the higher degree of similarity is designated as the top drawing number (d4).

Next, the drawing number having the highest degree of similarity to the selected drawing number is selected (d5), and it is judged whether or not there are a plurality of the corresponding drawing numbers (d6). The degree of similarity with the last selected figure number is compared, and the figure number having a high degree of similarity is selected (d7). If there is no plural drawing number in step (d6), it is judged whether or not the decision of the feeding order is completed (d8), and if not, step (d5).
Move to.

FIG. 30 is an explanatory diagram of the degree of similarity when the component type is weighted, and the occupied channel (occupied pitch) may differ depending on the component type. That is, the standard shape part may occupy one channel, but a deformed part having a wider width than the standard shape part may occupy a plurality of channels when the cartridge is mounted on the pallet. For example, the components a, b, and c whose occupied channel is 1, the components d, e, and f whose occupied channel is X (for example, 2), and the components g, h, i, and j whose occupied channel is Y (for example, 3). May exist. Therefore, the square root of the value of the occupied channel can be weighted. The degree of similarity in that case is obtained in the same manner as in the case of FIG. For example, the drawing number Z3 is "11100.
0y ^1/2 000 ", drawing number Z4 is" 001x ^1/2 00y "
^1/2 y ^1/2 y ^1/2 0 ", and since the parts d and g match, the similarity is expressed by the formula shown in the figure, and X =
If 2, Y = 3, then 4/72 = 0.0555.

The result of rearranging the parts use table by obtaining the similarity with such weighting is shown below. In this case, by grouping drawing numbers Z1, Z6, and Z2 into group 1 and drawing numbers Z3, Z5, and Z4 into group 2 by grouping, if there are eight types of parts that can be set in the knitting apparatus, for example, channels 1 to 1 For group 8, eight types of parts a, b, c, d, e, i, f, j are set, and for group 2, parts a, b, c, d, e, i, h. ，
8 types of g are set.

FIG. 31 is an explanatory view of grouping, and as described above, the drawing numbers rearranged by the similarity are A and
B, C, D, ... and the parts are a, b, c, d, ...
.. and the number of channels is 8, drawing numbers A, B, C,
D becomes group 1. The parts set corresponding to the channel numbers are a, b, c, d, e, f, g, h, the drawing numbers E, F, G, H are group 2, and the set parts are i, j, k, l, e, f, g, h.
In this case, the parts e, f, g and h do not need to be set up. The drawing numbers I, J, K, L are group 3, and the set parts are i, j, k, l, m, n, o,
p.

Similarly, when the number of channels is 10, the drawing numbers A to F are the group 1 and the drawing numbers G to L are the group 2, and the components are set for the 10 channels respectively. As described above, by performing the rearrangement according to the similarity, there is no limitation condition for the division of the grouping, the similarity between the drawing numbers is high in the group, and the efficiency of the knitting process can be achieved.

The present invention is not limited to the above-described embodiments, but can be applied to, for example, the manufacturing process of various devices other than the process of mounting components on a printed circuit board. Also, pallets, cartridges, reels, etc. on the assembly line are used to assemble printed circuit boards.
When applied to the manufacture of other devices, those suitable for the device can be used.

[0087]

As described above, according to the present invention, in the manufacturing control section 1, the manufacturing order is grouped to form the shipping order, and when the parts are shipped based on the shipping order, the assembly order is produced. The grouping process is performed based on the state of the assembly line 3 and the state of the assembly line 3, and it is possible to properly deliver the parts according to the state of the assembly line 3, and the assembly line can be produced without increasing the number of surplus parts on the assembly line. The operating rate of can be improved. Further, there is an advantage that the grouping processing time can be shortened by determining the input order based on the similarity. Further, there is an advantage that the number of times of changeover of parts can be reduced and the efficiency of the assembly line can be improved by appropriate grouping processing.

[Brief description of drawings]

FIG. 1 is a diagram illustrating the principle of the present invention.

FIG. 2 is an explanatory diagram of an example of the present invention.

FIG. 3 is an explanatory diagram of a manufacturing order, a delivery order, and an assembly order.

FIG. 4 is an explanatory diagram of work-in-order, parts table data, and process selection.

FIG. 5 is a flowchart of a shipping order determination process.

FIG. 6 is an explanatory diagram of grouping processing.

FIG. 7 is an explanatory diagram of grouping.

FIG. 8 is an explanatory diagram of a placement order determination and grouping process.

FIG. 9 is an explanatory diagram of creating a rack progress table.

FIG. 10 is an explanatory diagram of an in-process rack completion time.

FIG. 11 is an explanatory diagram of processing by urgent level determination.

FIG. 12 is an explanatory diagram of a processing selection table.

FIG. 13 is a flowchart of an order-of-input determination process.

FIG. 14 is an explanatory diagram of prioritization based on urgency.

FIG. 15 is an explanatory diagram of a placement order determination process based on a component commonality.

FIG. 16 is an explanatory diagram of creating a mounting data file.

FIG. 17 is an explanatory diagram of another insertion order determination process based on the component commonality.

FIG. 18 is an explanatory diagram of vector expression depending on use and non-use of parts.

FIG. 19 is an explanatory diagram of similarity definition between drawing numbers.

FIG. 20 is an explanatory diagram of a component usage table and a similarity table.

FIG. 21 is an explanatory diagram of a placement order determination process using a similarity table.

FIG. 22 is an explanatory diagram of a placement order determination process using a similarity table.

FIG. 23 is an explanatory diagram of a placement order determination process using a similarity table.

FIG. 24 is an explanatory diagram of definition of similarity between drawing numbers based on vector difference.

FIG. 25 is an explanatory diagram of a placement order determination process using a similarity table.

FIG. 26 is an explanatory diagram of a placement order determination process using a similarity table.

FIG. 27 is an explanatory diagram of a placement order determination process using a similarity table.

FIG. 28 is an explanatory diagram of sorting by similarity.

FIG. 29 is a flowchart of a throwing order determination process.

FIG. 30 is an explanatory diagram of the degree of similarity when the component type is weighted.

FIG. 31 is an explanatory diagram of grouping.

FIG. 32 is a schematic explanatory diagram of an example of an assembly line.

[Explanation of symbols]

 1 Manufacturing Management Department 2 Warehouse Management Department 3 Assembly Line 4 Assembly Line Management Department

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Jun Takayama 1015 Kamiodanaka, Nakahara-ku, Kawasaki-shi, Kanagawa Fujitsu Limited

Claims (10)

[Claims] 1. A manufacturing management unit (1) for creating a shipping order and an assembly order according to a manufacturing order, a warehouse management unit (2) for shipping parts according to the shipping order, and a warehouse management unit (2) for shipping. In the integrated manufacturing management system, the integrated manufacturing management system comprises an assembly line (3) for supplying assembly parts to perform assembly work, and an assembly line management unit (4) for controlling the assembly line (3) according to the assembly order. A manufacturing management unit (1) performs a grouping process on the manufacturing orders to form the delivery order, and performs a grouping process based on the manufacturing order and the state of the assembly line (3) to form the assembly order. An integrated manufacturing control system characterized by having a configuration. 2. The manufacturing management unit (1) determines a shipping processing target period based on the manufacturing order and a work-in-process quantity indicating a state of the assembly line (3) to form the shipping order. The integrated manufacturing management system according to claim 1. 3. The manufacturing management unit (1) selects a grouping condition for rounding and shipping based on the manufacturing order and a work-in-process quantity indicating a state of the assembly line (3), and sets the shipping order. The integrated manufacturing control system according to claim 1, wherein the integrated manufacturing control system is formed. 4. The manufacturing control section (1) includes a process selection file storing grouping conditions, and the grouping conditions stored in the process selection file based on a determination of increase or decrease of the in-process quantity of the assembly line (3). The integrated manufacturing control system according to claim 1, wherein 5. The assembly management section (1) cuts out a manufacturing order from a manufacturing order file and determines an assembly order based on a grouping condition from a process selection file and a work-in-process quantity of the assembly line (3). Is sent to the assembly line management unit (4).
Integrated manufacturing management system described. 6. The manufacturing management unit (1) or the assembly line management unit (4), the progress status of the work-in-process rack of the assembly line (3), and for each drawing number and each process according to the manufacturing order. Based on the standard man-hours, the completion time of the work-in-process rack is calculated, the urgency is calculated from the magnitude relationship between the completion time and the preparation time for the assembly line (3), and grouping processing according to the urgency is performed. The integrated manufacturing management system according to claim 1, further comprising a configuration for performing and sending an assembly command to the assembly line (3). 7. The assembly line management unit (4) obtains the similarity between drawing numbers according to the assembly order, determines a placement order in descending order of similarity, and performs a grouping process according to the placement order. The integrated manufacturing management system according to claim 1, further comprising a sequence determination processing unit. 8. The insertion order determination processing unit obtains the similarity by an angle or a difference between vectors having a value indicating use or non-use of a component type corresponding to a drawing number as an element. The integrated manufacturing control system according to claim 7. 9. The input order determination processing unit weights a value indicating the use or non-use of the component type according to the occupied pitch of the component type, and between the vectors having the weighted value as an element. The integrated manufacturing control system according to claim 7, wherein the degree of similarity between the drawing numbers is obtained from an angle or a difference. 10. The input order determination processing unit is provided with a similarity table in which the similarity between the drawing numbers is expressed in a matrix, and the rearrangement is performed in the descending order of the similarity in the similarity table, and the rearrangement is performed. The integrated manufacturing management system according to claim 7, wherein the order of introduction and the grouping process are performed in order of similarity.