JP2005242573A - Production line design system and production line design method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production line design system and a production line design method capable of designing a production line so as to cope with a future change of the production line. <P>SOLUTION: The production line design system comprises a process DB 3 that stores processes, the order of the processes, and the space of each process, required for a commodity produced in a production line to be designed; a production DB 4 that stores the order of the processes and the space of the processes in the existing production line; and a computer that obtains the processes required in the production line to be designed from the process DB 3 and all the processes of the existing production line from the production DB 4, removes the duplicating processes, and arranges the remaining processes according to the order of the processes for the commodity produced in the production line to be designed. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a production line design system and a production line design method.

  2. Description of the Related Art In recent years, computer design support systems have been used when designing production line configurations and layouts of process stages in factories.

For example, in designing a production line using a conventional computer-aided system, data necessary for product production is associated with the production process and stored in a computer, and a production line for a newly produced product is created. When placing, extract candidate data that can be diverted from the production line process of existing products stored in the computer, and determine whether the candidate data can be diverted to a new production line. These processes are arranged (Patent Document 1).
JP 2002-132323 A

  The conventional technology as described above has a problem in that no consideration is given to a case where a production line after completion is once changed.

  This is particularly the case with the above-mentioned conventional technology, such as when producing a variety of products in small quantities, producing a product with the same base product and changing it, or switching the line for an existing product of the same type. Even if it is possible to make a slight change to the production line that has already been completed, it is not possible to add or change processes because process changes and process space changes after that are not taken into consideration. All had to be redesigned, and as a result, the production line itself had to be rebuilt accordingly.

  Accordingly, an object of the present invention is to provide a production line design system and a production line design method capable of designing a production line so as to be able to cope with future changes in the production line.

  In order to solve the above problems, the present invention provides a process information storage means storing a process required by a product to be produced on a production line to be designed, a process order, and a process space required by each process, and an existing production line. Production line information storage means for storing the process order of the processes existing therein and the process space required for each process, the steps required in the production line designed from the process information storage means, and the production line information storage means A production line design means for acquiring all the processes of the existing production line from, removing duplicate processes from the processes, and arranging each process space by matching the remaining processes in the order of the processes of the product; , A production line design system.

  In addition, the present invention for solving the higher-level problems includes a step of acquiring a process required for a product to be produced in a production line to be designed, a process order, a process space required for each process, and an existing production line. The process, the process order, and the process space required by each process, the process of removing duplicate processes from all the acquired processes, and the remaining processes are matched in the process order of the product And a step of arranging each of the process spaces.

  According to the production line design system of the present invention, the process information storage means stores the process required by the newly designed product and the order of the processes, while the production line information storage means exists in the existing production line. The process and the order of the processes are stored, and the production line design means obtains and adds the processes necessary for the production line to be designed and the processes of the existing production line from these storage means, and overlaps these processes. Since the process space is removed and the process space of each remaining process is newly constructed, all the processes existing in the existing production line exist in the newly constructed production line. Even when the constructed production line is further changed, it is easy to change, and an extra process that does not exist in the existing production line is added. Not a can configure the production line by the number of steps required minimum.

  In addition, according to the production line design method of the present invention, the processes necessary for the production line to be designed and all the processes of the existing production line are added together, and the remaining ones are excluded except for those duplicated. Since the process space of each process is arranged as a newly constructed production line, all the processes existing in the existing production line will exist in the newly constructed production line, so the newly constructed production line will be further changed. In this case, the production line can be configured with the minimum number of necessary steps because it is easy to change and does not add extra steps that do not exist in the existing production line. it can.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

  FIG. 1 is a diagram showing a configuration of a production line design system (hereinafter sometimes simply referred to as a system) to which the present invention is applied. Here, the design of an automobile assembly production line will be described as an example.

  This system includes a computer 1 that performs design processing, a product database (product database is expressed as BD) 2 in which products are registered, and a process in which all processes necessary for producing products are registered. It consists of a database 3 and a production line database 4 in which processes of existing production lines and their order are registered.

  The computer 1 is a production line design means, and executes a process layout on the production line according to a procedure to be described later, and creates a production line design drawing based on the layout of the process space. The computer 1 is connected to an input device such as a keyboard and a mouse, and an output device such as a monitor and a printer, so that the design drawing can be output and corrected as appropriate.

  The product database 2 stores information on products manufactured on the production line as a database, and includes, for example, a computer 1 and a data storage device. Here, product information specifically refers to, for example, the product name of the automobile and the model of the product (sedan, wagon, one box, etc.), destination (for North America, for Japan, for Western Europe, etc.), for each model. The presence or absence of special parts is registered.

  The process database 3 is process information storage means for storing all processes necessary for assembling the product for each product, and for executing the equipment and processes used in the process for each process. The process space, equipment arrangement in the process, and the like are stored (these are referred to as process information). Therefore, the process database 3 stores process information necessary for products to be produced in a production line to be designed, process information of existing products, and the like. Such a database is constructed by a computer, for example.

  The equipment used in the process is all equipment (apparatus) necessary for carrying out the process for each process, for example, a robot, a transfer device, a parts shelf, and the like.

  The process space is all the space necessary for carrying out the process. For example, the space for installing the above equipment, the space necessary for performing the work, etc. is there.

  The equipment arrangement in the process is an arrangement of the equipment and work space in the process space.

  The production line database 4 is a production line information storage means, and is a database in which the order of each process, the process space required for each process, the layout of each process, etc. are stored as production line configuration information for an existing production line. is there. Such a database is constructed by a computer, for example.

  Here, for example, when there are a plurality of factories, all the production lines in each of these factories are stored for each production line and all the processes in the production line are stored. It is preferable. In addition, instead of collecting all production line information as a single database, it is possible to connect to each factory online and collect production line configuration information for each factory. Information storage means.

  In addition, such production line information may further include, for example, a factory name, a production line number in the factory, and the like as stored items.

  Next, a production line design procedure using this system will be described.

  Prior to the description, terms used will be briefly described.

  A production line usually consists of two types of lines: a main line and a sub-line.

  The main line consists of the processes that are necessary for assembling basic products that are common to all models.

  And each process which exists in this main line is called a base process. The base process is a process that is required to establish and meet a certain standard. The standard process is a process that is necessary for assembling automobiles arranged on the main line, and how much a model with a certain specification is produced. It corresponds to.

  Specifically, the necessary processes include an engine assembly process, an axle assembly process, a wheel (and peripheral parts) assembly process, an electrical component assembly process, an interior product assembly process, a panel assembly process, and the like. The process may be divided according to the number of production. For example, if the number of vehicles of a certain spec is small, for example, as a panel assembly process, a door panel, front grille, rear, fender, bonnet, etc. are assembled on one process stage. Each of these is divided and assembled at a plurality of process stages.

  Such a base process is arbitrarily determined and registered in advance in the process database 3 as a basic process.

  The sub-line is a line composed of processes necessary for assembling a product generated other than the main line, and a process performed in these sub-lines is referred to as an optional process. In the optional process, even if it is a car model flowing on the same main line, special parts that are specially assembled are assembled, or if production capacity exceeding the standard is required, There is a process (or apparatus) that replaces the process. The special part is, for example, a case where there are a car that is attached and a car that is not attached even in the same vehicle type, such as a sunroof. Similarly, resin parts painted in accordance with a special body color (two-tone or special color) may be used as special parts. It should be noted that the handling of such special parts is arbitrarily determined and is not particularly limited.

  These sublines include a line that needs to be synchronized with the main line and an unnecessary line.

  The sub-line that needs to be synchronized with the main line is a sub-line that assembles a part that is assembled on the main line and supplies it to the main line by assembling multiple parts by the time the main line is assembled. . Specifically, for example, when a car with a sunroof and a car without a sunroof flow on the same main line, the necessary parts for the sunroof installation are assembled according to the movement of the production car to which the sunroof is attached on the main line. It is a subline. For example, a line that supplies resin parts with paint colors that match a special color car.

  In addition, when the shoulder of the main line is temporarily used, it is necessary to synchronize with the processes before and after the main line.

  On the other hand, sub-lines that do not require synchronization with the main line, for example, assemble parts that are attached to almost all cars that flow on the main line, such as resin parts for general vehicles, interior parts, and instruments. It is a subline for.

  2 and 3 are flowcharts showing a production line design procedure.

  First, the computer 1 acquires information (product information) of a product produced on the production line to be designed from the product database 2 (S1). Here, the type of product manufactured in the production line designed this time (for example, whether it is a sedan or a wagon as a vehicle type) and vehicle structure information (such as the presence or absence of special parts) are obtained from the product database 2.

  Subsequently, from the acquired product information, a process, a process order, a process space, and the like necessary for production of the product are acquired from the process database 3 (S2). The processes acquired at this time are all processes of the base process and the optional process.

  Subsequently, the existing production line configuration information of each factory is acquired from the production line database 4 (S3). That is, here, the process, process order, and process space existing in the existing production line are acquired.

  Collect the production line configuration information (all existing processes and their order) of each factory to sum all processes, remove processes with the same function (that is, duplicate processes), and the remaining processes Are arranged as a sequence of production lines (S4). At this time, when the production line database 4 is constructed in advance, it is determined whether or not the process has the same function by adding the identification code indicating that the process has the same name or the same function to the process having the same function. Judgment is made from these names and identification codes.

  Subsequently, it is determined whether or not all the processes of the production line to be designed are completed (S5). Here, when all the processes are not complete, a process that is insufficient as a process of a product produced in the designed production line is added (S6). On the other hand, if all the processes are complete, the process proceeds to the next step S7 as it is.

  Up to this point, all the processes of the existing production line and all necessary processes in the production line to be designed are added, and a process is extracted from which redundant processes are removed.

  In the above procedure, all the processes of the existing production line are added together, and the process that is not enough as the process of the product to be produced on the production line to be designed is added to the process. When designing a production line for similar products, there are many cases where there are many processes that are the same as the existing production line processes. It is possible to reduce the number of processes for searching for and removing duplicate processes by adding only the processes in the line and removing duplicate processes, and then adding the processes that are lacking in design end production. is there. Therefore, the present invention is not limited to this, and all the processes of products produced on the production line to be further designed may be added to all the processes of the existing production line, and then the overlapping processes may be removed.

  A production line composed of a plurality of processes completed so far is referred to as a temporary line.

  FIG. 4 is a diagram schematically showing a production line configuration created in these steps in order to explain the processes in steps S4 and S5.

  Here, for example, when there are production lines for A car and B car as existing production lines, it is assumed that the processes exist in ST1 to ST4. In this case, as shown in FIG. 4 (a1), the steps necessary for the production of the A vehicle are ST1, ST2, and ST4, and the steps necessary for the production of the B vehicle are ST1 and ST4. Therefore, steps ST1, 2 and 4 are obtained from the existing production line as shown in FIG.

  As shown in FIG. 4 (a2), if the production line to be designed is for a C car, and ST1, 2, and 3, ST3 is sufficient for the existing production line shown in FIG. 4 (b). Is missing. Therefore, as shown in FIG. 4C, a temporary line in which processes ST1 to ST4 are arranged by adding process ST3 to the process of the existing production line is created.

  Next, the computer 1 determines whether each process in the temporary line including the processes extracted in steps 4 and 6 is a base process (S7). Here, if there is a process other than the base process (that is, an optional process) in each process, it is removed from the extracted temporary line (S8). As a result, only the base process remains.

  Next, the computer 1 arranges the process space of each process of the temporary line which is only the base process in the line arrangement space in the factory for constructing this production line (S9). This process is arranged so that the process space of each process obtained from the process database 3 is connected to the out of the process space and the next process space so that the process space can be accommodated in the factory. is there.

  Subsequently, the process arrangement conditions (line pitch, stage pitch, etc.) are adjusted (S10). At this time, a continuous equivalent function is a replaceable process.

  Subsequently, restrictions on the production line placement prohibited area are checked (S11). Production line placement prohibited areas are areas where process space should not be placed, such as factory pillars, transfer routes, robot operating ranges, areas where process stages have already been placed, etc. Register as a prohibited area in the factory. Here, when any one of the process spaces is included in the arrangement prohibited area, the arrangement of the process spaces is adjusted so that the process space exits the prohibited area (S12).

  Next, the computer 1 secures, as an empty space, a process space that is not necessary for the current product among the arranged processes (S13). In the example of FIG. 4, the process ST4 is not necessary for the production of the C car. However, since the process ST4 is also arranged as a base process in the previous step S4, the ST4 is used as a vacant space in the production line. Keep inside.

  As a result, when production of other vehicle types that require the process ST4 is performed, even when the line is changed, the process space can be replaced or moved only by arranging the equipment in the newly required process ST4. We can cope without. In addition, the process unnecessary this time is an empty space equivalent to an area equivalent to the process of another factory, and therefore, an unnecessarily empty space is not created.

  Subsequently, an optional process (subline) is arranged (S14). The optional process is installed outside the area where the base process is arranged and outside the prohibited area.

  Moreover, it is preferable to install near the place where the parts generated in the optional process are assembled.

  Finally, a process number (ID) is assigned only to a process necessary for a product produced on this production line (S15). At this time, the empty space is given an ID indicating a missing number or an empty space.

  The process ends here.

  As described above, according to the present embodiment, the necessary processes in the existing production line and the designed production line are added to eliminate duplicate processes, and only the base process is taken out of the processes to produce Since it is decided to arrange the process of the line, it is possible to arrange the process of the production line that can easily cope with the design of the production line for a new product, even if the product to be produced is changed It becomes.

  The present invention is suitable for designing a production line in an automobile production factory, and can be used to construct production lines for various products other than automobiles.

It is drawing which shows the structure of the production line design system to which this invention is applied. It is a flowchart which shows a production line design procedure. It is a flowchart which shows the production line design procedure following FIG. It is drawing for demonstrating arrangement | positioning of a production line.

Explanation of symbols

1 ... computer,
2 ... Product database,
3. Process database,
4 ... Production line database.

Claims (6)

Process information storage means for storing processes required by products to be produced in a production line to be designed, process order, and process space required by each process;
Production line information storage means for storing the process order of processes existing in the existing production line and the process space required for each process;
The process necessary for the production line to be designed is acquired from the process information storage means, and all the processes of the existing production line are acquired from the production line information storage means, and the redundant processes are removed from the process, and the process remains. Production line design means for arranging each process space in accordance with the process order of the products,
A production line design system characterized by comprising:   2. The production according to claim 1, wherein the production line design unit further deletes processes other than a predetermined basic process from all the acquired processes and arranges the remaining processes. Line design system.   The production line design means further arranges each remaining process in a place other than the production line arrangement prohibition area based on information of the production line arrangement prohibition area prepared in advance. 2. The production line design system described in 2. Obtaining the process required by the product to be produced in the production line to be designed, the process order, and the process space required for each process;
Obtaining a process, a process order, and a process space required for each process existing in an existing production line;
Removing duplicate processes from all acquired processes;
Arranging each process space by matching the remaining processes in the order of the processes of the products;
A production line design method characterized by comprising:   5. The production according to claim 4, further comprising the step of deleting a process other than a predetermined basic process from all the acquired processes before the step of arranging each remaining process. Line design method.   5. The step of arranging each remaining process arranges each process remaining in a place other than the production line arrangement prohibition area based on information of the production line arrangement prohibition area prepared in advance. Or the production line design method of 5.

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