JPH06730A - Production indication device for subassembly line - Google Patents

Abstract

PURPOSE:To cause subassembly lines and a kind and an amount of assemblies in a stock chute to cope with production plans for a main assembly line and variation of production at a real time. CONSTITUTION:Assemblies are assembled together at subassembly lines 1 and fed to a main assembly line 3 through stock chutes 2. A kind and an amount of assemblies under assembly present in the subassembly lines are detected by a first detecting means. The assemblies in the stock chutes are detected by a second detecting means. Results detected by the first and second detecting means are added and the addition result is compared with a line condition to achieve production plans for the main assembly line and computed. A production indication for assemblies in an amount lower than an amount for a line condition is outputted to the first process of the main assembly line and a production stop indication for assemblies in an amount higher than an amount for the line condition is outputted thereto.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production instruction device for a sub-assembling line.

[0002]

2. Description of the Related Art In a unit assembly line for engines, transmissions, etc., a plurality of sub-assembly lines for assembling the assembly are arranged beside the main assembly line, and the assembly assembled by the sub-assembly line is
It is supplied to the main assembly line via a stock chute.

By the way, in the mixed production system for producing a wide variety of products in small quantities, for example, as a production instructing means for the preceding process,
A so-called ordering point method is adopted in which when the stock is consumed and a certain lower limit ordering point is reached, the production type and quantity are ordered for each predetermined lot size. According to this ordering point method, based on the monthly production plan, a pallet at the ordering point on the stock line is provided with a signal signboard with the production conditions entered, and the pallet with this signal signboard is used in the subsequent process. When the goods are delivered, the signal signboard is removed from the pallet and sent to the lot process upstream of the line, and the production instruction is given to the lot process.

However, regarding the production instruction of the sub-assembling line in the mixed production system, in addition to mixing various kinds of products,
Since the production plan of the main assembly line is often changed, such an ordering point system cannot be adopted. That is, in order to prevent so-called stockouts on the stock chute, it is necessary to adjust the type and quantity of the assembly to be fed to the sub-assembling line in accordance with the product type and quantity on the main assembling line. Since this adjustment must correspond to the production status on the main assembly line, it is basically different from the production instruction to the previous process by the signal signboard. For this reason, conventionally, an operator in charge of the first first process of the sub-assembling line, while staring at the product flow state of the main assembling line, actually relies on experience and intuition to select the sub-assembling line. The type, quantity, and order of assembly to be introduced were decided.

[0005]

When determining the type of assembly to be put into the sub-assembling line by the conventional method, the operator must check the assembly sunk after the first step in the sub-assembling line. Since it is difficult to accurately grasp the type and quantity, if there is a change in the form and quantity of the products produced on the main assembly line, the assembly required for the first process will be handled appropriately in response to the change. Can not be thrown. This can result in so-called stockouts in the stock chute that lack the required assembly at all. If the stock chute is lengthened, the stock quantity of the assembly can be increased, so that the possibility of stockout can be reduced. However, it is difficult to take a large space for the stock chute on the side of the main assembly line, and when the stock chute is lengthened, it becomes difficult to move the assembly from the stock chute to the main assembly line. That is, the stock shot should be short if possible.

[0006]

SUMMARY OF THE INVENTION The present invention provides a sub-assembling line for supplying an assembly to a main assembling line through a stock chute, in which the type and quantity of the assembly being assembled in the sub-assembling line are determined. The first detection means for detecting, the second detection means for detecting the type and quantity of the assembly in the stock chute, and the detection results from the first and second detection means are added, and the addition result is obtained. Comparing and calculating with the line conditions for achieving the production schedule of the main assembly line, giving the production instruction of the assembly of which the quantity is smaller than the line conditions to the first step of the sub-assembling line, and (EN) A production instructing device for a sub-assembling line, comprising: means for giving an instruction to stop production of an assembly in a quantity larger than the line condition.

[0007]

The type and quantity of the assemblies in the sub-assembling line and the stock chute are detected by the first and second detecting means. On the other hand, in order to achieve the mixed production plan on the main assembly line, the types and quantities of assemblies required are set as line conditions. This line condition is rewritten at any time when the production plan is changed. The detection results of the first and second detection means are added, the addition result and the line condition are compared and calculated, and for the assembly less than the required amount, the production instruction is given to the first step of the sub-assembling line. For assemblies that are given to the sub-assembly line in excess of the required amount, the production discontinuation instruction is given to the first step of the sub-assembly line.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which the present invention is applied to an assembling line of a vehicle differential assembly will be described below with reference to the drawings.

FIG. 1 schematically shows the positional relationship between the sub-assembling line 1, the stock chute 2 and the main assembling line 3. In the main assembly line 3, products placed on a pallet or the like flow in the direction of the arrow. The sub-assembling lines 1 are arranged in a plurality of rows beside the main assembling line 3, and the assembly necessary for the main assembling line 3 is supplied from the stock chute 2. The stock chute 2 can accommodate a plurality of assemblies, and a worker or a transfer machine near the main assembly line 3 takes out the required assembly from the stock chute 2 and assembles the product on the main assembly line 3. . Information about the assembly in the sub-assembling line 1 and the stock chute 2 is input to the computer 4, and the information about the production instruction is transmitted from the computer 4 to the sub-assembling line 1.

Each sub-assembling line 1 has a plurality of steps as shown in FIG. 2 (three steps in the figure), and the assembly is completed while moving from the first step to the third step. The completed assembly is supplied to the main assembly line 3 through the stock chute 2. Figure 2 shows sub-assembly line 1
Although each process is separated because it is conceptually displayed, the first process to the third process are actually continuous.

In each process, the boxes from 1 to 5 represent the number of work in progress. The number of work-in-progress is the number of assemblies being assembled. In the frame, 3AT and 4AT represent the differential gear for 3-speed automatic transmission and the differential gear for 4-speed automatic transmission, respectively. One 3AT in the first step,
It is shown that the second step has two 3ATs and one 4AT, and the third step has one 3AT and two 4ATs.
Information on the type and quantity of assembly in each process is detected by the first detection means (not shown), and the type and quantity of assembly in the stock chute 2 is detected by the second detection means (not shown). It Various sensors of contact type or non-contact type can be used for the first and second detecting means. The detection results of the first and second detection means are added and then input to the comparison calculation unit 5. The frequency of this detection and input is, for example, a 3-second cycle to ensure real-time responsiveness. Line conditions necessary for achieving the production plan on the main assembly line 3 (information about the type and quantity of the required assembly) are input in advance to the comparison calculation unit 5, and the line conditions and the addition result are By comparing, it is determined whether or not the type and quantity of the assembly in the sub-assembly line 1 are appropriate, that is, whether or not there is an excess or deficiency for each type of assembly.

The number of assemblies in the sub-assembling line 1 can be adjusted by operating the computer 4, for example, as shown in FIG.
Is displayed on the CRT in the form of. Fig. 3 shows 3AT, 4AT
Both indicate that there are four. In the figure, the standard number of products in progress is the number of assemblies that satisfy the line conditions.
The standard number of in-process works per AT is 4. The maximum in-process number is the upper limit in the case of non-steady-state production such as pre-production or drive-in production. Here, the maximum in-process number is 7 for 3AT and 6 for 4AT. Preceding production means moving the sub-assembling line when the main line is stopped to make a so-called make-up pool.Incremental production means reducing the number of workers when the sub-assembling line is behind the main line. Increase to shorten the cycle time. In the past, it was impossible to issue such production instructions in real time.

Next, the operation of the present invention will be described. Now
The line conditions for achieving the production plan of the main assembly line 3 are 5 for 3AT and 4 for 4AT. The line conditions are for many other assemblies, but are omitted here for simplicity. Sub assembly line 1
The number of assemblies in the stock chute 2 is detected by the first and second detection means, and the total of the detection results is 4 3AT and 4AT.
This information is input to the comparison calculation unit 5 and compared with the line condition. As a result, it can be seen that one extra 3AT is required, but 4AT is in time. The computer 4 instructs the first step of the sub-assembling line 1 to produce one 3AT based on the calculation result. On the contrary, for example, if there are five 4ATs and one more, the computer 4 instructs the first step to "do not produce" 4ATs. In this way, the type and quantity of the assembly in the sub-assembling line 1 necessary for carrying out the production plan in the main assembling line 3 are properly controlled in real time, so that the assembly in the stock chute 2 can be controlled. It is possible to reliably prevent shortages and excess.

Next, consider the case where both 3AT and 4AT are less than the standard in-process number. For example, 3 3AT,
When there are three 4ATs, the number of deficient 3ATs is 5-3 = 2.
Then, the shortage number of 4AT is 4-3 = 1. This is 4A
It means that 3AT must be produced urgently than T. With this equipment, it is instructed to preferentially produce assemblies that are far apart from the line conditions on the negative side. As a result, the tight condition of the required assembly can be promptly resolved even in the case of a sudden change in the production plan.

Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications can be made. For example, the above-mentioned embodiment is applied to the assembly line of the differential assembly of the engine, but the present invention can be applied to the assembly line of various other assemblies.

[0016]

As described above, the present invention compares the types and quantities of assemblies (line conditions) required by the main assembly line with the types and quantities of assemblies in the sub assembly line and the stock chute. Since the production instruction and the production stop instruction are issued to the first process of the sub-assembling line in real time so as to match the two, it is possible to prevent the stock chute from being out of stock and excessive in the assembly,
The optimal quantity of assembly can always be kept as stock. In addition, by rewriting the line conditions, it is possible to deal with non-steady-state production such as pre-production and drive-in production.

[Brief description of drawings]

FIG. 1 is a conceptual diagram showing the overall configuration of the present invention.

FIG. 2 is a diagram showing types and quantities of assemblies in a sub-assembling line and a stock chute.

FIG. 3 is a diagram showing a total quantity of assemblies by type in a sub-assembling line and a stock chute.

[Explanation of symbols]

 1 Sub assembly line 2 Stock chute 3 Main assembly line 4 Computer

Claims (2)

[Claims] 1. A sub-assembling line for supplying an assembly to a main assembling line via a stock chute, comprising first detecting means for detecting the type and quantity of the assembly being assembled in the sub-assembling line. , The second detection means for detecting the type and quantity of the assembly in the stock chute and the detection results from the first and second detection means are added, and the addition result is added to the production plan of the main assembly line. To obtain a production instruction for an assembly in a quantity smaller than the line condition, and to an assembly in a quantity larger than the line condition for the first step of the sub-assembling line. And a means for giving a production discontinuation instruction, and a production instruction device for a sub-assembling line, comprising: 2. The production instructing apparatus for a sub-assembling line according to claim 1, wherein production instructions for an assembly having a larger distance from the line condition on the minus side are prioritized.