Component manufacturing system and component manufacturing method

Abstract

A component manufacturing system (100, 100A) includes a main base (10), a first production base (20), and a second production base (30). The main base (10) designs a common wire harness (B1) and an optional wire harness (OP). The main base has a first order function of determining the quantity of the common wire harness to be produced based on the provisional order information and placing an order with the first production base, and a second order function of obtaining order confirmation information (41b) from a customer at a timing closer to the delivery date than the provisional order information and placing an order for the completed wire harness with the second production base based on the confirmation information.

Description

Technical Field

[0001] The present invention relates to a component manufacturing system and a component manufacturing method, which can be used by a component manufacturer that manufactures a wiring harness as a vehicle component based on customer requirements. Background Art

[0002] Generally, a wiring harness installed in a vehicle such as an automobile is an assembly of electric wires and has a complex shape, which is integrally formed by bundling a large number of various types of electric wires. The wiring harness is used to connect a power source such as a battery in a vehicle to various electrical components on the vehicle, or to connect multiple electrical components to each other. The wiring harness includes a large number of connectors to facilitate the attachment and detachment of wire connection portions.

[0003] For example, the wiring harness manufacturing method and the wiring harness manufacturing apparatus of JP-A-2017-152154 disclose techniques for reducing an increase in manufacturing cost when manufacturing a wiring harness having various configurations according to various required specifications. Specifically, when forming a wiring harness obtained by combining a basic bundle having a basic specification with one or more selectable optional bundles, the specification of the basic bundle and the specification of the optional bundles are specified according to order information. The configuration of a common circuit in the specification of the optional bundles is extracted, the extracted common circuit is integrated into the specification of the basic bundle, and the configuration of the common circuit is deleted from the specification of the optional bundles, so that a plurality of intermediate structures are manufactured based on the data obtained by rearranging the common circuit, and the wiring harness is manufactured by combining the plurality of intermediate structures. Summary of the Invention

[0004] Meanwhile, based on requirements such as specifications, quantities, delivery dates, etc. determined by a vehicle manufacturer as a customer each time, a component manufacturer that manufactures a wiring harness for a vehicle manufactures a finished wiring harness product that meets the requirements before the delivery date, and delivers its finished product to the customer before the specified delivery date. Since there are various types, grades, destinations, etc. of vehicles in which the wiring harness is installed, the component manufacturer manufactures various types of wiring harnesses respectively managed by different product numbers according to the requirements of the vehicle manufacturer, etc.

[0005] On the other hand, considering human resources related to the manufacturing of the wiring harness, ensuring various manufacturing facilities, manufacturing costs, etc., it may be necessary to manufacture the wiring harness overseas outside Japan where the vehicle is manufactured.

[0006] However, when a component manufacturer imports a wiring harness manufactured overseas from an overseas country to Japan and delivers the imported wiring harness to a customer in Japan, it takes about 2 to 3 weeks from the transport of the wiring harness in the overseas country to its arrival in Japan, so that the component manufacturer needs to consider the problem of the delivery date of the wiring harness to be delivered to the customer.

[0007] Specifically, after the component manufacturer confirms the final quantity of the wire harnesses to be delivered to the customer for each product number, the delivery cycle of the wire harnesses from the component manufacturer to the customer is only a few days. Therefore, when manufacturing wire harnesses overseas, it is necessary to complete the manufacturing of the corresponding wire harnesses and start exporting the wire harnesses from the overseas factory before confirming the final quantity of the wire harnesses to be delivered for each product number of the wire harnesses.

[0008] Therefore, in order to deliver the confirmed quantity of wire harnesses to the customer before the delivery date without any shortage, it is necessary for the component manufacturer to consider the possibility of an increase or decrease in the predicted quantity before the confirmed quantity of the wire harnesses, manufacture and import a sufficiently large quantity of wire harnesses overseas. Therefore, it is necessary to manufacture additional wire harnesses that are not actually delivered, which also requires storage space, resulting in a factor of high cost. However, when the component manufacturer reduces the quantity of wire harnesses that should be sufficiently manufactured and imported overseas, depending on the quantity of wire harnesses required finally confirmed by the customer, the component manufacturer may not be able to prepare the wire harnesses before the delivery date, making the possibility of a shortage higher.

[0009] According to an embodiment, the component manufacturing system and the component manufacturing method can avoid the occurrence of excessive inventory of wire harnesses, and can also be used for the component manufacturer to deliver the quantity of wire harnesses required by the customer before the delivery date without any shortage.

[0010] According to an embodiment, a component manufacturing system can be used by a component manufacturer that manufactures wire harnesses as vehicle components based on customer demand.

[0011] The component manufacturing system includes:

[0012] A main base; and

[0013] A first production base and a second production base located in different regions from each other,

[0014] wherein the main base has the function of designing a common wire harness commonly used for multiple vehicle product numbers and multiple optional wire harnesses different for each product number based on the planned information from the customer,

[0015] The first production base has the function of producing the common wire harness based on the order instruction from the main base,

[0016] The second production base is closer to the delivery location specified by the customer than the first production base,

[0017] The second production base has the function of obtaining the common wire harness from the first production base, combining the common wire harness with the optional wire harness based on the order instruction from the main base, and delivering the completed wire harness to the delivery location, and

[0018] The main base has a first order function of determining the quantity of common wire harnesses to be produced based on the temporary order information and placing an order with the first production base, and

[0019] a second order function of obtaining order confirmation information from the customer at a time closer to the delivery date than the temporary order information and placing an order for the completed wire harnesses with the second production base based on the confirmation information.

[0020] According to an embodiment, a component manufacturing method can be used by a component manufacturer that manufactures wire harnesses as vehicle components based on customer requirements.

[0021] The component manufacturing method includes:

[0022] using the main base and a first production base and a second production base located in different regions from each other;

[0023] a function provided by the main base of designing common wire harnesses commonly used for a plurality of vehicle product numbers and a plurality of optional wire harnesses different for each product number based on the planned information from the customer;

[0024] a function provided by the first production base of producing the common wire harnesses based on the order instruction from the main base,

[0025] arranging the second production base closer to the delivery location specified by the customer than the first production base; and

[0026] a function provided by the second production base of obtaining the common wire harnesses from the first production base, combining the common wire harnesses with the optional wire harnesses based on the order instruction from the main base, and delivering the completed wire harnesses to the delivery location,

[0027] wherein the main base includes a first order step of determining the quantity of common wire harnesses to be produced based on the temporary order information and placing an order with the first production base,

[0028] a transportation step of transporting the common wire harnesses produced by the first production base to the second production base, and

[0029] a second order step of obtaining order confirmation information from the customer at a time closer to the delivery date than the temporary order information and placing an order for the completed wire harnesses with the second production base based on the confirmation information.

[0030] According to an embodiment, a component manufacturing system manufactures wire harnesses as vehicle components at the main base and at a first production base and a second production base located in different regions from each other.

[0031] The main base includes:

[0032] Function of designing a common wiring harness commonly used for multiple vehicle product numbers based on planned information from customers and multiple optional wiring harnesses different for each product number;

[0033] Function of sending design information for manufacturing the common wiring harness to the first production base;

[0034] First order function of determining the quantity of the common wiring harness to be produced based on temporary order information and placing an order with the first production base;

[0035] Function of sending design information for manufacturing a completed wiring harness by combining the common wiring harness and optional wiring harnesses to the second production base; and

[0036] Second order function of obtaining order confirmation information from the customer at a timing closer to the delivery date than the temporary order information and placing an order for the completed wiring harness with the second production base based on the confirmation information. Description of the Drawings

[0037] Figure 1 is a block diagram illustrating a configuration overview of a component manufacturing system according to a first embodiment of the present invention.

[0038] Figure 2 is a diagram illustrating Figure 1 a functional configuration example of a main part of the component manufacturing system.

[0039] Figure 3 is a schedule diagram illustrating the timing and process of processing in each part of the component manufacturing system.

[0040] Figure 4 is a block diagram illustrating a functional configuration example of a main part of a component manufacturing system according to a second embodiment of the present invention.

[0041] Figure 5A is a plan view illustrating an example of the combination of wiring harness components, and Figure 5B is a plan view illustrating an example of the manufactured wiring harness.

[0042] Figure 6 is a flowchart illustrating an example of a process for optimizing the configuration of a wiring harness.

[0043] Figure 7 is a schematic diagram illustrating an example of a display form of a list of optional components for each wiring harness product number.

[0044] Figure 8 is a front view of a main part of a screen display example of a list of optional components for each wiring harness product number.

[0045] Figure 9It is a front view of the main part of a screen display example that is the result of depicting a sub-common part as a grouped optional part.

[0046] Figure 10 It is a front view of a display example showing the additional part configuration of each wire harness product number, the number of additional parts, the total number of parts, etc. Detailed Description of the Invention

[0047] Hereinafter, specific embodiments of the present invention will be described with reference to the corresponding drawings.

[0048] (First Embodiment)

[0049] <Outline of the Component Manufacturing System>

[0050] Figure 1 The configuration outline of a component manufacturing system 100 according to the first embodiment of the present invention is illustrated.

[0051] Preparation Figure 1 The component manufacturing system 100 shown is used by a component manufacturer that manufactures a wire harness (W / H) which is a main component to be installed in a vehicle such as an automobile or an intermediate component thereof. Before starting mass production of the vehicle, the component manufacturer that manufactures the wire harness generally designs the wire harness based on the planned information obtained from a customer (e.g., a vehicle manufacturer). After that, when an order for the wire harness is received at each predetermined cycle, the component manufacturer manufactures the required number of wire harnesses that meet the specifications specified by the customer and delivers the manufactured wire harnesses to the specified delivery location before the specified delivery date.

[0052] The number of days from after the content of the customer's order (i.e., the final confirmation of the number of wire harnesses (vehicles) for each product number) until the delivery date of the corresponding wire harness product by the component manufacturer is generally expected to be 2 to 4.

[0053] On the other hand, when a component manufacturer imports a wire harness manufactured overseas into Japan and delivers the imported wire harness to a customer within Japan, the cycle required for the imported wire harness is about 2 to 3 weeks.

[0054] Therefore, when manufacturing a wire harness overseas, it is necessary to complete the manufacturing of the corresponding wire harness and start exporting from the overseas factory before confirming the final quantity of the wire harness to be delivered for each product number. Therefore, it is also necessary for the component manufacturer to pre-manufacture an additional number of wire harnesses exceeding the quantity required by the customer, resulting in unnecessary costs due to the excess wire harnesses not being delivered to the customer.

[0055] Figure 1 The component manufacturing system 100 shown has functions useful for the component manufacturer to reduce the costs associated with the above-mentioned excess wire harnesses.

[0056] The component manufacturing system 100 includes a main base 10, a first production base 20, and a second production base 30 as bases used by a component manufacturer that manufactures the wiring harness PP. It is assumed that each of the first production base 20 and the second production base 30 is, for example, a factory of a related subsidiary of a component manufacturer that manufactures wiring harness products.

[0057] Here, it is assumed that the first production base 20 is located in a distant area such as a foreign country, and it is assumed that the second production base 30 is located in a location such as domestic, which is closer to the customer's delivery location 42 than the first production base 20. That is, the component manufacturing system 100 includes the first production base 20 and the second production base 30. The first production base 20 can manufacture components that allow for a long transportation time to a location close to the customer, and the second production base 30 can deliver the manufactured components to the customer within a short time period.

[0058] The customer's order department 41 orders the required wiring harness PP products from the main base 10 of the component manufacturer based on the production plan of automobiles, etc. at the customer. It is expected that the production plan (the production quantity planned for each vehicle model) at the customer will change according to circumstances. After that, the specifications and quantities of each product number of the wiring harness PP officially ordered from the component manufacturer are confirmed.

[0059] Therefore, as Figure 1 shown, the main base 10 of the component manufacturer independently obtains temporary order information 41a and confirmation information 41b as orders for the wiring harness from the customer at different timings. The temporary order information 41a is periodically sent from the customer's order department 41 to the main base 10 at a frequency such as once a month. Alternatively, the temporary order information 41a can be obtained from the customer's order department 41 through the operation of the main base 10. After the specifications and quantities of each product number are confirmed at the customer, the confirmation information 41b is sent from the customer to the main base 10 a few days before the delivery date.

[0060] At the main base 10, in order to manufacture the wiring harness PP of each product number to be delivered to the customer as a product, the basic part B1 and the optional part OP (the second manufacturing specification information D2 described later) of the wiring harness are designed in advance based on the plan information from the customer (the first manufacturing specification information D1 described later). The basic part B1 is a sub-harness formed only by components commonly provided in the wiring harnesses of multiple product numbers or all product numbers. The optional part OP is a sub-harness corresponding to the differential configuration specific to each wiring harness having different specifications for each product number. That is, the sub-harness of the basic part B1 and the sub-harnesses of various optional parts OP are combined with each other so that the wiring harness PP of the product that can satisfy the specifications of the wiring harnesses of various product numbers can be formed respectively.

[0061] The main base 10 sends information on the sub-beams of the basic part of the design to the first production base 20 in advance, and the first production base 20 constructs a production line for manufacturing the sub-beams. The main base 10 sends the first order information 10a containing the quantity of the required sub-beams to the first production base 20 and places an order for the basic part B1 to be manufactured in the first production base 20. The first production base 20 manufactures the sub-beams of the basic part B1 according to the first order information 10a sent from the main base 10. The first production base 20 inspects the manufactured sub-beams of the basic part B1 and then conducts "transportation 20a of the basic part B1". That is, the basic part B1 is exported from a foreign country and delivered to the second production base 30 within Japan.

[0062] Here, it takes one week or more to transport from the first production base 20 to the second production base 30. However, since the first production base 20 manufactures the sub-beams of the basic part B1 based on the first order information 10a ordered after the provisional order information 41a, the basic part B1 can be delivered to the second production base 30 at a time when there is still sufficient time left until the delivery date of the wire harness of the product.

[0063] After receiving the confirmation information 41b from the order department 41 of the customer, the main base 10 sends the second order information 10b to the second production base 30 and orders the manufacturing and delivery of the wire harness of the product at a time when the delivery date of the product is met. The second order information 10b contains the specifications and confirmed quantities for each product number, information on each optional part OP, etc. The second order information 10b may contain information on the basic part B1.

[0064] The second production base 30 sequentially receives the sub-beams of the basic part manufactured at the first overseas production base 20. The second production base 30 manufactures the corresponding optional parts OP of the required quantity according to the second order information 10b. According to the product specifications for each product number, the second production base 30 combines each manufactured optional part OP with the sub-beams of the basic part B1 received from the first overseas production base 20 and manufactures the wire harness PP of the product, so as to meet the delivery date. The second production base 30 conducts "transportation 30a of the wire harness" and delivers the wire harness PP of the product of each product number to the delivery location 42 of the customer.

[0065] Here, since the second production base 30 is closer to the delivery location 42 of the customer than the first production base 20, it is easy to shorten the time required for the transportation until the manufactured wire harness PP is delivered to the delivery location 42 of the customer. Since the second production base 30 does not need to manufacture the sub-beams of the basic part B1, the number of days required from the generation of the second order information 10b to the delivery of the wire harness PP of the product can be shortened.

[0066] Since the first production base 20 manufactures and exports sub-beams of the basic part B1 according to the first order information 10a generated at the timing in response to the temporary order information 41a, the basic part B1 can be delivered to the second production base 30 at a timing that leaves sufficient time for the delivery date of the wire harness of the product, even if it takes multiple days for the transportation 20a of the basic part B1.

[0067] Since the second production base 30 combines sub-beams of the basic part B1 with each optional part OP to manufacture the wire harnesses PP of the products of each product number, the error between the number of wire harnesses of each product number ordered in the confirmation information 41b and the usage amount of the manufactured basic part B1 can be reduced. That is, not only can the excess amount of each manufactured optional part OP be reduced to almost zero, but it is also not necessary to excessively manufacture the wire harnesses PP of all products of each product number at the overseas production base as in the past and transport and store the manufactured wire harnesses PP. By establishing the first production base 20 overseas, it becomes easier to secure human resources, manufacturing facilities, etc., so that the manufacturing cost can be further reduced.

[0068] <Functional configuration example of the main part>

[0069] Figure 2 Illustrated is Figure 1 a functional configuration example of the main part in the component manufacturing system 100.

[0070] <Functions of the main base 10>

[0071] Figure 2 The main base 10 shown in

[0072] includes an order reception management server 11, a basic part design function 12, an optional part design function 13, and an order management server 14.

[0073] The basic part design function 12 is a function of designing sub-beams of the basic part B1 based on the wire harness specifications of each vehicle product number provided in the first manufacturing specification information D1 (or the temporary order information 41a) acquired by the order reception management server 11. The sub-beams of the basic part B1 correspond to a part that is commonly provided in the wire harnesses PP of all product numbers or multiple product numbers of the components, that is, the basic elements. Usually, multiple types of sub-beams are independently generated as the basic part B1. For example, it is assumed that multiple types (such as sub-beams for connecting engine-related components, sub-beams for connecting various electrical components around the steering wheel, etc.) are separately generated as different types of basic parts.

[0074] The basic part design function 12 can automatically design the sub-beams of the basic part B1 and can only include functions that support the design work in response to the input operations of the designer.

[0075] The optional part design function 13 is a function of designing sub-beams of a plurality of optional parts OP based on the wiring harness specifications of each vehicle product number provided in the first manufacturing specification information D1 (or the provisional order information 41a) acquired by the order receiving management server 11. The sub-beams of the optional parts OP correspond to the sub-beams obtained by extracting only a part of the unique parts in the wiring harnesses of each product number from among the parts of the wiring harnesses PP of a plurality of product numbers different from each other in type. The optional part design function 13 can automatically design the sub-beams of the optional parts, or can only include functions that support the design work in response to the input operations of the designer.

[0076] Therefore, the sub-beams of the basic part B1 designed by the basic part design function 12 and one or more of the sub-beams of the optional parts OP designed by the optional part design function 13 are combined with each other, so that the entire wiring harness of any product number, that is, the wiring harness PP of the product to be delivered to the customer, can be formed.

[0077] The order management server 14 has a function of sending the first order information 10a to the first production base 20 at a timing slightly later than the timing of generating the provisional order information 41a based on the information of the sub-beams of the basic part B1 designed by the basic part design function 12. The order management server 14 has a function of sending the second order information 10b to the second production base 30 at a timing slightly later than the timing of generating the confirmation information 41b based on the information of the sub-beams of the optional parts OP designed by the optional part design function 13 and the information of the sub-beams of the basic part B1. It is assumed that, for example, a digital communication line (such as the Internet) is used for the communication between the order management server 14 and the first production base 20, and the communication between the order management server 14 and the second production base 30.

[0078] The order receiving management server 11, the basic part design function 12, the optional part design function 13, and the order management server 14 can be implemented by combining the hardware of one or more communicable computers with the software required for performing their respective functions.

[0079] <Functions of the First Production Base 20>

[0080] Figure 2 The first production base 20 shown in < > includes an order receiving management server 21, a basic part manufacturing facility 22, and an export management facility 23.

[0081] The order receiving management server 21 has a function of receiving the first order information 10a from the main base 10. Based on the information on the required quantity related to the sub-beam specification of the basic part B1 provided in the received first order information 10a, the design information obtained in advance, etc., the order receiving management server 21 further generates instructions for ensuring components such as wires, terminals, connectors, etc. required for manufacturing the basic part, and instructs the basic part manufacturing facility 22 to start manufacturing after ensuring the above components.

[0082] The basic part manufacturing facility 22 has a function of actually manufacturing the sub-beams based on the information on the required quantity related to the sub-beams of the basic part B1 obtained from the order receiving management server 21, etc. Specifically, the basic part manufacturing facility 22 is implemented by a facility that automatically performs corresponding steps (such as cutting each wire, installing terminals on each wire, installing connectors, arranging a large number of wires, winding tapes, installing external members, assembling, inspecting, etc.) or a facility that supports the manual work of workers. For inspection, continuity inspection between multiple terminals of the sub-beam and visual inspection by workers are performed. Specialized facilities can be used to support the inspection by workers.

[0083] The export management facility 23 exports the sub-beams of each basic part B1 manufactured by the basic part manufacturing facility 22 using a predetermined transportation route, and performs a management process such that the sub-beams are delivered to the location of the second production base 30 within a predetermined period. The cycle from the start of the export process of the basic part B1 at the first production base 20 until the basic part B1 is delivered to the second production base 30 can fluctuate due to differences in the country and region where the first production base 20 is located, and since its transportation is by sea, for example, it requires a cycle of about 1 to 3 weeks.

[0084] <Functions of the second production base 30>

[0085] Figure 2 The second production base 30 shown in [figure number] includes an order receiving management server 31, an optional part manufacturing facility 32, a basic part acquisition management section 33, a product manufacturing facility 34, a product inspection function 35, and a product transportation management function 36.

[0086] The order receiving management server 31 has a function of receiving the second order information 10b from the main base 10. Based on the information on the required quantity related to the sub-beam specification of each optional part OP provided in the received second order information 10b, the design information received in advance from the main base 10, etc., the order receiving management server 31 generates instructions to ensure components such as wires, terminals, connectors, etc. required for manufacturing each optional part OP, and instructs the optional part manufacturing facility 32 to start manufacturing after ensuring the components.

[0087] The optional part manufacturing facility 32 has a function of actually manufacturing the optional sub-beams for each product number based on the design information of the sub-beams of each optional part OP obtained from the order receiving management server 31. Specifically, the optional part manufacturing facility 32 is implemented by a facility that automatically performs corresponding steps (such as cutting each wire, installing terminals on each wire, installing connectors, arranging a large number of wires, winding tape, installing external components, assembling, inspecting, etc.), or by a facility that supports the manual work of workers.

[0088] The basic part acquisition management section 33 acquires the basic part B1 delivered as a result of transporting 20a the basic part B1 from the first production base 20, performs an acceptance inspection of the basic part B1 as needed, and then manages the basic part B1 so that the basic part B1 can be supplied to the product manufacturing facility 34 according to the product manufacturing schedule at the second production base 30.

[0089] The product manufacturing facility 34 has a function of manufacturing the wire harness PP by combining one or more specific optional parts OP selected from a large number of optional parts OP manufactured by the optional part manufacturing facility 32 according to the product number of each product with one basic part B1 acquired by the basic part acquisition management section 33. Specifically, the product manufacturing facility 34 is implemented by a facility that automatically performs corresponding steps (such as arranging in a state where multiple sub-beams are combined with each other, inserting terminals into the cavities of each connector, winding tape, installing external components, etc.), or by a facility that supports the manual work of workers.

[0090] The product inspection function 35 has a function of inspecting whether each of the wire harnesses PP manufactured by the product manufacturing facility 34 meets the specifications of the wire harness PP for each product number to be delivered. Specifically, the product inspection function 35 is implemented by a facility that automatically performs corresponding steps (such as continuity inspection between connector terminals, appearance inspection, etc.), or by a facility that supports the manual work of workers.

[0091] The product transportation management function 36 arranges the transportation 30a of the wire harness PP so that the inspected wire harness PP can be delivered to the customer's delivery location 42 before the customer-specified delivery date.

[0092] <Example of the timing and process of processing>

[0093] Figure 3 Illustrated is a representative example of the timing and process of processing in each part of the component manufacturing system 100. The following will describe Figure 3 the example. Based on the plan information from the customer (for example, based on the wire harness design method to be described later), the main base 10 of the component manufacturing system 100 designs the basic part B1 and the optional part OP in advance.

[0094] For example, the production plans of customers such as automobile manufacturers are generated at various times and subsequently changed according to circumstances. However, even if the content of the production plan has not been confirmed, at a certain time point t1 (e.g., once a month), the order department 41 of the customer also places a provisional order (S11) for the wire harness PP as a component to the main base 10 of the component manufacturer based on the production plan at that time point. That is, unconfirmed information (such as specifications, required quantities, etc.) for each product number of the wire harness PP is provided to the component manufacturer.

[0095] Based on the provisional order information obtained from the customer, the main base 10 of the component manufacturer formulates a production plan (S12) for the wire harness PP of the product to be delivered. The wire harness to be designed is configured as a combination of a basic part B1 and an optional part OP, and at least the production quantity of the basic part B1 that exists regardless of the difference in product numbers is determined at this time point. The optional part OP is the remaining components after the basic part B1 is excluded from the wire harness of each product number, and the production plan of the optional part OP can also be customized to a certain extent at this time point.

[0096] The main base 10 of the component manufacturer sends the information including the content of the designed basic part B1 and its required quantity to the first production base 20 as the first order information 10a (S13).

[0097] Based on the first order information 10a obtained from the main base 10, the first production base 20 starts the production of the basic part B1 (S14).

[0098] After manufacturing the basic part B1, the first production base 20 starts transportation at a certain time point t12 to deliver the manufactured basic part B1 to the second production base 30 (S15). Since this transportation involves import and export and the long-distance transportation is carried out by sea, the required transportation period T2 is, for example, about two weeks.

[0099] The second production base 30 can receive the basic part B1 transported from the first production base 20 at a certain time point t13 (S16).

[0100] On the other hand, the production plan of the customer such as the automobile manufacturer (i.e., the specifications and required quantities of the wire harness PP for each product number) is confirmed at a certain time point t2, and a few days later, the component manufacturer needs to deliver the required wire harness PP to the delivery location 42 of the customer before a certain time point t4. Therefore, the order department 41 of the customer sends the confirmation information 41b to the main base 10 of the component manufacturer at this time point (S21).

[0101] That is, the delivery date (T1) for the component manufacturer from confirming the specifications and quantities of the wire harness PP to delivering the wire harness PP is about a few days.

[0102] When the confirmation information 41b is obtained at a certain point in time, the main base 10 of the component manufacturer places an order with the second production base 30, where the wire harness PP of the product to be manufactured and delivered based on the confirmation information 41b is used as the second order information 10b (S22). Specifically, the main base 10 sends the second order information 10b, which includes information such as the required quantity of various types of optional parts OP needed to form the wire harness PP for each product number, the specifications of the wire harness PP for each product number, and the required quantity.

[0103] At the moment when the second order information 10b is obtained from the main base 10, based on the information, the second production base 30 starts manufacturing each optional part OP (S23).

[0104] After manufacturing each optional part OP, the second production base 30 combines one or more of these optional parts OP with the basic part B1 obtained from the first production base 20, and one or more of these optional parts OP and the basic part B1 are assembled to be integrated with each other, thereby manufacturing the wire harness PP of the product for each product number (S24).

[0105] After inspecting the wire harness PP of the product for each product number manufactured, the second production base 30 transports and delivers the wire harness PP to the customer's delivery location 42, and delivers the wire harness PP at the time point t3 before the delivery date t4 (S25, S26).

[0106] That is, when the first production base 20 is overseas, the number of days required for transportation increases, such that when production starts at the time point t2 when the customer confirms the specifications and quantity of the wire harness PP, the wire harness PP cannot be delivered before the delivery date t4. However, since the specifications of the basic part B1 are common to the wire harness PP of all product numbers, the basic part B1 can be specified by the main base 10, and its production can start at the first production base 20 before the specifications of the wire harness PP are confirmed, and the basic part B1 can be delivered to the second production base 30 at a certain timing close to the time point t2 when the specifications and quantity of the wire harness PP are confirmed. Since the basic part B1 is common to the wire harness PP of all product numbers, the excessive quantity of the basic part B1 manufactured by the first production base 20 can be reduced to the minimum value.

[0107] In Figure 3 In the example shown, the second production base 30 does not start manufacturing the optional part OP until the time point t2 when the second order information 10b is generated. However, even before confirming the final delivery quantity (Nx) for each product number, the manufacturing of the optional part OP for the minimum required quantity (No: No < Nx) that is expected can be started in advance at a time point before the second order information 10b is generated.

[0108] (Second Embodiment)

[0109] Figure 4 FIG. illustrates a functional configuration example of a main part of a component manufacturing system according to a second embodiment of the present invention.

[0110] Figure 4 The component manufacturing system 100A shown in is Figure 1 a modification of the component manufacturing system 100 shown in. The following description will omit elements that are the same as those of the component manufacturing system 100 and are denoted by the same reference numerals.

[0111] Figure 4 The component manufacturing system 100A shown in includes a main body part 10A and a delivery part 10B belonging to the main base 10 of the component manufacturer, a first production base 20, an intermediate base 50, and a second production base 30. That is, the delivery part 10B that performs the process of delivering the harness PP of the product to the customer's delivery position 42 is separated from the main body part 10A of the main base 10 and exists as an independent department. An intermediate base 50 that relays between the first production base 20 and the second production base 30 is added.

[0112] In the main body part 10A of the main base 10, the temporary order management server 11A receives temporary order information 41a from the order department 41 of the customer. Based on the plan information (the first manufacturing specification information D1 described later) received in advance from the order department 41 of the customer, the basic part design function 12 designs sub-harnesses of components that are common to the harnesses PP of multiple product numbers or all product numbers. This design information is sent to the first production base 20 in advance. Based on the plan information (the first manufacturing specification information D1) received in advance from the order department 41 of the customer, the optional part design function 13 designs multiple types of sub-harnesses of the optional part OP among the components provided in the harnesses of multiple product numbers. The design information is sent to the second production base 30 in advance. Each product number's harness PP is formed by combining a sub-harness of one basic part B1, one or more types of optional parts OP, and other additional components Pa.

[0113] The order management server 14A of the main body part 10A sends the first order information 10a to the first production base 20. The first order information 10a includes information on the required quantity of the basic part B1 designed by the basic part design function 12. Information on each optional part designed by the optional part design function 13 is sent to the confirmation information management server 11B of the delivery part 10B at the timing when this information is required.

[0114] Based on the ordered quantity of the sub - bundles according to the first order information 10a, the first production base 20 manufactures sub - bundles of the basic part B1, and when the manufacturing is completed, the first production base 20 starts the transportation process so that the manufactured basic part B1 is delivered to the intermediate base 50.

[0115] The intermediate base 50 includes a basic part acceptance inspection section 51, a basic part extraction section 52, and a server (not shown). The server of the intermediate base 50 manages information representing the specifications and quantities of the basic parts B1 received by the intermediate base 50 and sent to the second production base 30. The basic part acceptance inspection section 51 receives the basic parts B1 exported and imported from the first production base 20 and conducts an appearance inspection to check whether the required specifications of the basic parts B1 are met. This appearance inspection is carried out by using an automated inspection facility or a facility that supports visual inspection by workers.

[0116] The basic part extraction section 52 of the intermediate base 50 extracts the basic part B1 that has completed the inspection and passed the inspection in the basic part acceptance inspection section 51 at an appropriate timing (i.e., usually on the same date and time as the generation of the confirmation information 41b), and conducts the process of delivering the basic part B1 to the second production base 30.

[0117] When the order department 41 of the customer sends the confirmation information 41b, the confirmation information management server 11B of the delivery section 10B receives the confirmation information 41b. The confirmation information management server 11B confirms the quantity of the wire harnesses PP of each product number to be delivered by the delivery section 10B through the confirmation information 41b. The confirmation information management server 11B sends information such as the design information of each optional part OP, the information on the combination of the basic part B1 and the optional part OP for each product number, or the quantity of the wire harnesses PP of each product number as the second order information 10b to the second production base 30.

[0118] At the second production base 30, the order receiving management server 31 receives the second order information 10b from the delivery section 10B. Next, the order receiving management server 31 instructs the optional part manufacturing facility 32 to start manufacturing each necessary optional part OP. On the other hand, the basic part acquisition management section 33 of the second production base 30 can receive the basic part B1 manufactured at the first production base 20 via the intermediate base 50 at a timing close to the same date and time as the generation of the confirmation information 41b.

[0119] For each product number of the wire harness, by combining one or more optional parts OP selected from among the various types of optional parts OP manufactured by the optional part manufacturing facility 32 with the basic part B1 received by the basic part acquisition management section 33, the product manufacturing facility 34 of the second production base 30 can manufacture the wire harness PP in a short time period.

[0120] The product inspection function 35 of the second production base 30 performs continuity inspection between a plurality of terminals of the wire harness PP manufactured by the product manufacturing facility 34 and appearance inspection of the wire harness PP. Next, the wire harness PP that has passed the inspection is transported and delivered to the delivery section 10B of the main base 10.

[0121] The delivery section 10B of the main base 10 delivers the wire harness PP received from the second production base 30 to the customer's delivery location 42 before the customer-specified delivery date.

[0122] As described above, for the component manufacturing systems 100 and 100A according to the embodiments of the present invention, since even if manufacturing starts before confirming the delivery quantity of the wire harnesses for each product number, the components manufactured at the first production base 20 in a distant location (such as overseas, etc.) can be limited to the basic part B1, shortages are eliminated and there is no need for overproduction of the wire harnesses PP for each product number to be delivered to the customer, so that costs can be reduced. Even if it takes a long time for the transportation of the basic part B1 involving import and export, the required quantity of the basic part B1 can be supplied to the second production base 30 at a timing close to the generation of the confirmation information 41b. Therefore, even if the period from confirming the quantity of the wire harnesses PP for each product number to be delivered to the customer to the delivery date is short (such as a few days), the wire harnesses PP can be delivered to the customer before the delivery date without causing shortages and a large number of excess components by using an overseas factory.

[0123] In the above description, the case where the optional part OP is manufactured at the second production base 30 and the manufactured optional part OP is combined with the basic part B1 is described, and in a state where the optional part OP is manufactured at a base different from the second production base 30, the optional part OP can be delivered to the second production base 30. In this case, the base for producing the optional part OP is set at a location where the optional part OP can be delivered to the second production base 30 within a short time period. This base can obtain the design information of the optional part OP from the main base 10 in advance. When the second order information 10b is obtained from the main base 10, the second production base 30 places an order for the optional part OP required for manufacturing the wire harness PP with this base.

[0124] <Method for Designing a Wire Harness>

[0125] Hereinafter, a method for designing a wire harness that can be used in a component manufacturing system will be described.

[0126] <Example of Wire Harness Configuration>

[0127] Figure 5A An example of the combination of wire harness components is shown, and Figure 5B An example of the manufactured wire harness PP is shown.

[0128] For example, when receiving an order for a wiring harness from a customer such as an automobile manufacturer, a component manufacturer that manufactures components of the wiring harness PP receives first manufacturing specification information D1, which represents the specifications of the corresponding wiring harness. Therefore, the component manufacturer manufactures the wiring harness PP based on the first manufacturing specification information D1. The first manufacturing specification information D1 is usually sent from the customer at a timing earlier than the provisional order information 41a.

[0129] For example, basically, the wiring harness PP is an assembly of a circuit that connects one terminal of an electrical component provided on a vehicle to one terminal of another electrical component provided on the vehicle, and is formed by bundling a large number of wire groups arranged along a predetermined wiring path. Usually, terminals for connection are pressed at the ends of each wire, and the terminals of each wire are mounted on a predetermined part of a predetermined connector. A predetermined part on the outer side of the wiring harness is covered with a protective outer material.

[0130] Therefore, in a simplified configuration, for example, the wiring harness PP becomes Figure 5B the shape shown. The automobile manufacturer manufactures various types of vehicles, and these vehicles have different circuit configurations and wiring paths respectively, depending on differences in destinations, grades, etc. Therefore, it is necessary to independently manufacture a large number of types of wiring harnesses PP managed by different product numbers respectively. The allowable period from confirming the quantity of the wiring harness PP to be produced for each product number until the component manufacturer delivers the wiring harness PP is very short, for example, about several days.

[0131] Therefore, the component manufacturer needs to efficiently manufacture and prepare the required quantity of the wiring harness PP for each product number within a short time period without excess or shortage. It is also necessary to reduce the manufacturing cost. To meet the above conditions, the component manufacturer conceived a manufacturing method for the wiring harness PP, designed second manufacturing specification information D2 for efficiently manufacturing the wiring harness PP based on the first manufacturing specification information D1, and manufactures the wiring harness PP for each product number according to the designed second manufacturing specification information D2.

[0132] When applying the wiring harness design method of the present invention, Figure 5A the basic part B1, the additional part OB, and the additional component Pa shown in are respectively manufactured in advance and combined with each other for assembly, so as to manufacture Figure 5B the wiring harness PP shown in.

[0133] The basic part B1 is a component of a part of the entire product wiring harness PP, and indicates a component commonly provided in the wiring harnesses PP of all product numbers, that is, a sub-harness formed only by main common components.

[0134] The actual basic part B1 is manufactured as each independent sub - beam of the corresponding system for a plurality of wiring parts grouped on an automobile. For example, the sub - beams of the basic part B1 respectively connected to the steering wheel system, the engine system, the transmission system, the braking system, etc. are designed and manufactured as intermediate parts independent of each other.

[0135] The additional part OB is a sub - beam formed by a plurality of components (optional components), and the plurality of components form the remaining components after the configuration of the basic part B1 is excluded from the entire wiring harness PP of each product number. The additional part OB is formed only by the optional components commonly provided in the wiring harnesses of a plurality of product numbers, that is, the sub - common components. The optional components targeted to be sub - common components are limited to components that meet specific conditions. Specifically, as will be described later, among the components of the wiring harnesses of a plurality of product numbers predicted to be mass - produced, components with a usage rate equal to or greater than a predetermined value are selected.

[0136] In fact, sub - beams of various types of additional parts OB are designed and manufactured as intermediate parts independent of each other, depending on the situation of the systems within the vehicle. Each of the additional parts OB is an intermediate part formed by, for example, several to dozens of wires, terminals, connectors, etc.

[0137] The additional component Pa is each of the remaining components among the optional components, which are sub - common components not used as any of the additional parts OB. Each of the additional components Pa is a small part formed by, for example, one to several wires, terminals, connectors, etc.

[0138] Therefore, assemble the sub - beams of the basic part B1 (in fact, its multiple sub - beams), one or more sub - beams of the additional part OB selected according to the product number, and the remaining necessary additional components Pa, as Figure 5B shown, so that the wiring harness PP of any product number can be formed.

[0139] The important fact in this article is that the sub - beams of the basic part B1 are formed only by the main common components, and in addition, the sub - beams of the additional part OB are formed only by the sub - common components. Therefore, even if the quantity of the wiring harness PP of each product number required by the customer fluctuates, when the change in the total number of the wiring harnesses PP independent of the product number is small, there will be no excess or shortage in the sub - beams of the basic part B1. Therefore, even if the manufacturing of the sub - beams of the basic part B1 starts before confirming the quantity of the wiring harness PP of each product number required by the customer, problems are unlikely to occur.

[0140] Sub-beams of the additional part OB can be assembled into wire harnesses PP of various types of product numbers. Thus, for example, when the quantity required for one of the wire harnesses PP of two types of product numbers that can use the same sub-beams of the additional part OB increases and the quantity required for the other decreases, the quantity required for the additional part OB remains almost unchanged, so that the problem of excess or shortage in the manufacturing quantity hardly occurs. Therefore, even if the manufacturing of the sub-beams of the additional part OB starts before the quantity of the wire harnesses PP of each product number required by the customer is confirmed, the problem hardly occurs.

[0141] In particular, preferably, components with a usage rate equal to or greater than a predetermined value are selected as secondary common components from among the components of wire harnesses of multiple product numbers predicted to be mass-produced, so that the possibility that the sub-beams of the additional part OB can be used as intermediate components of wire harnesses common to various product numbers can be increased, and the number of common intermediate components can also be increased. Therefore, even if the period from the confirmation of the quantity required for the wire harnesses of each product number to the delivery of these wire harnesses PP is short, it becomes easy to manufacture the required quantity of wire harnesses PP of each product number without excess or shortage, and an efficient manufacturing process can be achieved.

[0142] <Process of optimizing the configuration of wire harnesses>

[0143] Figure 6 An example of the process of optimizing the wire harness configuration when implementing the wire harness design method according to the present invention is illustrated. That is, the component manufacturer manufacturing the wire harness PP performs Figure 6 the processing shown therein, so that the second manufacturing specification information D2 can be designed, and the configuration of the second manufacturing specification information D2 is optimized based on the first manufacturing specification information D1 provided by the customer in order to efficiently manufacture the wire harness PP.

[0144] In fact, by using a design support device (not shown), the designer of the component manufacturer can perform Figure 6 the processing shown therein. In the same way as a general computer system, the design support device can be configured by combining a hardware configuration including a central processing unit (CPU), a storage device, an input device, a display, a communication device, etc., a dedicated application software for reading and processing the first manufacturing specification information D1, and a dedicated software for implementing the characteristic functions of the present invention ( Figure 6 each step in). Hereinafter, the Figure 6 processing process will be described.

[0145] For example, in a vehicle manufacturer, the configuration of the electrical system and the routing path of the wire harness change according to the type of vehicle in which the wire harness PP is installed, so that separate wire harnesses PP with different product numbers and specifications need to be prepared for each type of vehicle before starting the manufacturing of the vehicle.

[0146] The design support device installed in the company of the component manufacturer communicates with the computer of the vehicle manufacturer as the customer, thereby obtaining first manufacturing specification information D1 (S31) representing the specifications of the wiring harness PP for each product number. This process is carried out at a timing that leaves sufficient time until the delivery date of the corresponding wiring harness PP. The content of the first manufacturing specification information D1 includes design drawing data necessary for manufacturing the target wiring harness PP, a specification list information for each product number, and a physical wiring diagram.

[0147] Based on the first manufacturing specification information D1, the design support device extracts all components (circuits, such as individual wires, etc.) that commonly exist in the wiring harnesses PP of all product numbers as main common components Pc1 (S32).

[0148] The design support device determines the configuration of the sub-harness of the basic part B1 formed only by a large number of main common components Pc1 extracted in S32 (S33). In the embodiment, a large number of main common components Pc1 are divided into 6 types of groups for each vehicle system, and are configured as sub-harnesses of the basic part B1 that are independent for each group. For example, a plurality of sub-harnesses of the basic part B1 that are independent for each group (such as for the steering wheel system, for the engine system, for the transmission system, for the braking system, etc.) are generated.

[0149] The design support device classifies each remaining component among the components forming the wiring harnesses PP of all product numbers, excluding all main common components Pc1 extracted in S32, as an optional component Po (S34).

[0150] The design support device obtains the predicted production quantity Np of the wiring harness PP for each product number and the usage rate Ur of each component (S35).

[0151] For example, it is assumed that the predicted production quantity Np for each product number is determined to be the same as or close to the number of vehicles of each vehicle type that the vehicle manufacturer plans to produce before producing the vehicle. That is, since the same number of wiring harnesses PP as the number of vehicles to be produced for each vehicle type is required, the predicted production quantity Np of the wiring harness PP for each product number is expected to be the same as the number of vehicles of each vehicle type planned to be produced by the vehicle manufacturer.

[0152] The usage rate Ur (usage rate) of each component can be calculated by the following formula.

[0153] Ur = (sum of the usage quantities of each component for each product number) / (total planned W / H quantity of all product numbers)

[0154] The design support device displays a list of components for each product number of the wiring harness PP in tabular format on the screen (S36). Here, Figure 7A specific example of the content to be displayed on the screen is illustrated. The content will be described later.

[0155] Regarding the content of the S36 list on the screen, the design support device updates the display content (S37) by rearranging the items (row units) of each product number in descending order of the predicted production quantity Np of each product number.

[0156] The design support device updates the display content (S38) by rearranging each component of the content of the list on the screen in descending order of the usage rate Ur.

[0157] Figure 8 A specific example of the updated screen after performing step S38 is illustrated. The content will be described later.

[0158] The design support device extracts a plurality of secondary common components Pc2 from among a large number of optional components Po displayed on the screen (S39).

[0159] The design support device determines the configuration of the sub-beams of a plurality of additional portions OB formed only by the secondary common components Pc2 extracted in S39 (S40).

[0160] Figure 9 A specific example of the updated screen after performing steps S39 and S40 is illustrated. Figure 10 A specific example of the correspondence between the wire harness PP of each product number and the sub-beams of each additional portion OB is illustrated. The content thereof will be described later.

[0161] Regarding the processing of each of steps S39 and S40, it is assumed that in practice, a designer or the like determines whether the optional component Po is an appropriate component based on the content displayed on the screen, and selects the secondary common component Pc2, or determines the configuration of each additional portion OB, and gives an instruction to the CPU of the design support device through an input operation such as a keyboard to perform the processing. However, it is also possible to automate the determination made by the designer or the like in S39 and S40 based on some rules and various conditions using a predetermined program.

[0162] The design support device classifies each of the remaining components among the optional components Po that are not selected as any of the common components Pc2 as additional components Pa (S41).

[0163] The design support device determines the content of the second manufacturing specification information D2 such that Figure 5B as shown, the configuration of the wire harness PP of each product number is a combination of a sub-beam of the basic portion B1, a sub-beam of one or more additional portions OB, and additional components Pa.

[0164] <Display example of the list of optional components for each product number>

[0165] Figure 7 An example of a display mode of a list Po of optional components for each product number of a wire harness PP is illustrated.

[0166] In Figure 7 the example, the list of components (corresponding to individual wires, etc.) that form each of the wire harness product numbers N1, N2, N3, …, Nm to be manufactured is arranged horizontally in each row. For each product number, the components provided in the corresponding wire harness PP and the components not provided therein are indicated by the presence or absence of hatched lines in a rectangular pattern.

[0167] For example, in the wire harness PP of product number N1, each component with part names A1 and A2 is provided, and each component with part names A3 and A4 is not provided. On the other hand, in the wire harness PP of product number N2, each component with part names A1 and A3 is provided, and each component with part names A2 and A4 is not provided. The wire harness PP of each product number also includes components that form the basic part B1, but in Figure 7 the example, the components of the basic part B1 are excluded, and only the optional components Po are illustrated.

[0168] Below each component row, numerical values U1, U2, U3, ..., Un (e.g., values in % units) of the usage rate Ur of the corresponding component are illustrated. The usage rate Ur represents the ratio of the total number of components of each product number used to the total planned quantity of the wire harness PP. In Figure 7 the values X1, X2, X3, ..., Xm of the planned quantity of the wire harness of each product number X are arranged on the right side of each wire harness product number N. The sum of the planned quantities of the wire harnesses of each product number X is the total planned quantity of the wire harness PP.

[0169] In Figure 6 step S36 shown in Figure 7 the list Po of optional components shown in

[0170] can be displayed on the screen in a table format. Attached to the optional components Po, the list of each main common component Pc1 provided in the basic part B1 can be displayed on the same screen simultaneously. Figure 7 Thus, a user such as a designer who operates the design support device can easily grasp the component configuration of each wire harness product number N by referring to the screen as

[0171] shown. The product number N of each component, the usage rate Ur, the planned quantity of the wire harness of each product number X, etc. can be grasped.

[0172] Figure 8The screen display example of the list of optional components of the harness PP for each product number is illustrated. Figure 8 The main part is illustrated on the screen.

[0173] From Figure 7 the state of the list of the shown optional components Po, the design support device rearranges the items in each row in descending order of the predicted production quantity Np of the harness PP for each product number from top to bottom in row-by-row order ( Figure 6 S37 in ). The design support device also rearranges the columns of each optional component Po in descending order of the usage rate Ur of each component from the left column to the right column in column-by-column order ( Figure 6 S38 in ). Therefore, the screen as shown in Figure 8 can be displayed.

[0174] In Figure 8 , the use or non-use of each component for each product number is represented by the presence or absence of hatching in each small rectangular pattern.

[0175] In Figure 8 , the ranges of the component areas Z1 and Z2 are shown. The component area Z1 represents the range of the group of components with a high usage rate Ur of each component among the optional components Po of the harness PP of the product numbers where the planned quantity of the harnesses forming each product number X is large (for example, the threshold is 100 units or more), and is displayed in a state distinguished from others as a rectangular range on the upper left side of the screen.

[0176] The component area Z2 represents the range of the group of components with a large usage rate Ur of each component among the optional components Po of the harness PP of the product numbers where the planned quantity of the harnesses forming each product number X is less than Z1 (for example, the threshold is less than 100 units), and is displayed in a state distinguished from others as a rectangular range on the lower left side of the screen.

[0177] That is, since a large number of frames of the optional components Po are formed within the ranges of the component areas Z1 and Z2, as shown in Figure 8 , design can be carried out, which facilitates the manufacture of the harness PP of each product number through the configuration of the parts of the design frame. Specifically, when the sub-harness of the additional part OB, which is a set of components common to the harnesses PP of multiple product numbers among the optional components Po, is configured as a common intermediate component, the number of components of the harness PP including the intermediate component can be significantly reduced. At the same time, since the common intermediate component can be used as any component of the harnesses PP of multiple product numbers, the common intermediate component can be used to adjust the increase or decrease in the quantity of the harnesses PP to be produced for each product number. The common intermediate component can also enable the manufacture of the required quantity of the harnesses PP of each product number within a short delivery date.

[0178] <Screen display example as a result of grouping sub-common components>

[0179] Figure 9 An example of a screen display showing the result of grouping the sub-common component Pc2 of the optional component Po is illustrated. Figure 9 The main part on the screen is illustrated.

[0180] In Figure 9 In the above-mentioned component area Z1, each optional component Po is displayed as a set of sub-common components Pc2-A, Pc2-B, and Pc2-C divided into three types of groups and the state of the remaining additional components Pa. On the actual screen observable by the designer's eyes, the differences between the corresponding groups of sub-common components Pc2-A, Pc2-B, and Pc2-C and the differences from the remaining additional components Pa are displayed as differences in the color of the rectangular display pattern.

[0181] Here, for example, Figure 9 The set of 23 corresponding sub-common components Pc2-A provided in the leftmost first to twentieth columns, twenty-fifth column, twenty-sixth column, and twenty-eighth column in the wire harness of the product number in the first row is also provided in the wire harnesses of other product numbers in the fourth, fifth, and ninth rows in the same way. Therefore, the set of 23 sub-common components Pc2-A is grouped into one group and assigned as a component forming a sub-bundle of an additional part OB.

[0182] Each additional component Pa provided in the wire harness of the product number in the first row is assigned to the remaining components obtained by excluding all sub-common components Pc2-A from the optional components Po forming the wire harness of that product number.

[0183] In the same way, in Figure 9 The set of 5 corresponding sub-common components Pc2-B provided in the fifth to eighth columns and thirtieth column in the wire harness of the product number in the second row is also provided in the wire harnesses of other product numbers in the third and eighth rows in the same way. Therefore, the set of 5 sub-common components Pc2-B is grouped into one group and assigned as a component forming a sub-bundle of an additional part OB.

[0184] Each additional component Pa provided in the wire harness of the product number in the second row is assigned to the remaining components obtained by excluding the sub-common component Pc2-B from the optional components Po forming the wire harness of that product number.

[0185] In Figure 9In the above, in the component area Z2, each optional component Po is shown as being divided into a set of sub-common components Pc2-D, Pc2-E, and Pc2-F that are divided into three types of groups and the state of the remaining additional components Pa. On the actual screen, the differences between the groups of the corresponding sub-common components Pc2-D, Pc2-E, and Pc2-F and the differences from the remaining additional components Pa are shown as differences in the colors of the rectangular display patterns.

[0186] Here, for example, in Figure 9 a set of 3 corresponding sub-common components Pc2-D in the first column, second column, and ninth column on the left provided in the wire harness of the product number in the first row in the area Z2 is also provided in the wire harnesses of other product numbers in the second row to the fifth row, eighth row, and sixteenth row in the same way. Therefore, the set of 3 sub-common components Pc2-D is grouped into one group and is assigned as a sub-bundle component of an additional part OB.

[0187] In Figure 9 a set of 4 corresponding sub-common components Pc2-E in the seventh row, eighth row, eighteenth row, and twentieth row in the area Z2 is also provided in the wire harnesses of other product numbers in the ninth row to the twelfth row. Therefore, the set of 4 sub-common components Pc2-E is grouped into one group and is assigned as a sub-bundle component of an additional part OB.

[0188] Each additional component Pa provided in the wire harness of the product number in the first row of the component area Z2 is assigned to the remaining components obtained by excluding the sub-common components Pc2-D and Pc2-E from the optional components Po that form the wire harness of the product number.

[0189] That is, as Figure 9 shown, by extracting the sub-common components Pc2 that are commonly provided in the wire harnesses PP of multiple product numbers and performing more appropriate grouping, the configuration of each sub-bundle of multiple additional parts OB can be determined. By performing appropriate grouping, the number of components in the wire harness PP of each product number can be reduced (the intermediate components are counted as one component), making it easy to adjust for fluctuations in the number of wire harnesses PP required for each product number.

[0190] Figure 9 The work of extracting and grouping the sub-common components Pc shown can actually be determined by the judgment of the designer or can be automatically processed by a program.

[0191] <Display examples of additional part configuration, number of additional components, total number of components, etc.>

[0192] Figure 10An example of display showing the additional part configuration, the number of additional components, the total number of components, etc. for each product number of the wire harness PP is illustrated.

[0193] In Figure 10 the example, the combinations of the additional parts OB-A to OB-F formed by the six groups of sub-common components Pc2-A to Pc2-F shown in Figure 9 the additional number of the additional component Pa, and the total number of components NT are displayed in the list for each product number of the wire harness PP.

[0194] In Figure 10 for example, the wire harness PP of the product number (B111) shown in the first row is formed by a sub-harness of one additional part OB-A and 10 additional components Pa, such that the total number of components NT is 11 (1 + 10). In fact, the optional component and the basic part B1 are combined to form the wire harness PP of one product number.

[0195] For example, the wire harness PP of the product number (Z423) shown in the third row is formed by sub-harnesses of two types of additional parts OB-B and OB-C and 11 additional components Pa, such that the total number of components NT is 13 (2 + 11).

[0196] Each additional component Pa is a small component formed by about one to several wires. The number of wires provided in each of the additional parts OB-A to OB-F is about several to several tens. As Figure 10 shown in

[0197] by appropriately grouping the corresponding sub-common components Pc2 to form the corresponding additional parts OB-A to OB-F, the number of additional components forming the entire wire harness PP can be reduced, for example, by about half.

[0198] The production of sub - bundles of the basic part B1, which is a component of the wiring harness PP, can start at a time sufficiently early with respect to the delivery date of the wiring harness PP to the customer. Thus, by using a base located far from the delivery location (such as an overseas production base, etc.), the basic part B1 can be manufactured and transported over a long distance, and the basic part B1 can be used as a component of the wiring harness PP. By using a base close to the delivery destination (such as a domestic production base, etc.), the production of sub - bundles of each additional part OB can start even before the quantity of the wiring harness PP for each product number required by the customer is confirmed. The production of the minimum quantity of the corresponding additional components Pa can start by predicting the expected fluctuations in the quantity of the wiring harness PP for each product number required by the customer before the actual required quantity is confirmed.

[0199] According to an embodiment, the component manufacturing system (100, 100A) can be used by a component manufacturer that manufactures wiring harnesses as vehicle components based on customer requirements.

[0200] The component manufacturing system (100, 100A) includes:

[0201] A main base (10); and

[0202] A first production base (20) and a second production base (30) that are located in different regions from each other, where

[0203] The main base has functions (basic part design function 12, optional part design function 13) of designing a common wiring harness (basic part B1) that is commonly used for multiple vehicle product numbers and multiple optional wiring harnesses (optional parts OP) that are different for each product number based on planned information (first manufacturing specification information D1) from the customer.

[0204] The first production base has a function (order receiving management server 21, basic part manufacturing facility 22) of producing the common wiring harness based on an order instruction from the main base.

[0205] The second production base is located closer to the delivery location (customer delivery location 42) specified by the customer than the first production base.

[0206] The second production base has functions (basic part acquisition management section 33, order receiving management server 31, optional part manufacturing facility 32, product manufacturing facility 34) of obtaining the common wiring harness from the first production base, combining the common wiring harness with the optional wiring harness based on an order instruction from the main base, and delivering the completed wiring harness to the delivery location, and

[0207] The main base also has a first order function (order management server 14, first order information 10a) of determining the quantity of the common wiring harness to be produced based on temporary order information and placing an order with the first production base, and

[0208] A second order function (order management server 14, second order information 10b) that obtains order confirmation information (41b) from a customer at a timing closer to the delivery date than the temporary order information and places an order for the completed wire harness with the second production base based on the confirmation information.

[0209] By using the component manufacturing system having the above configuration, it is possible to avoid the occurrence of an excessive inventory of wire harnesses. That is, the components produced at the first production base can be limited to a common wire harness common to a plurality of product numbers, so that even if the common wire harness is manufactured in advance before the required quantity of the wire harness for each product number is confirmed, the quantity of the excessive common wire harnesses generated that are not used for this delivery can be reduced to the level of fluctuations in the number of vehicles. Even if the first production base is located overseas, the second production base is also located at a position close to the delivery location, so that the time required to transport from the second production base to the delivery location is shortened, and it becomes easy to deliver the quantity of the completed wire harnesses for each product number required by the customer without any shortage before the delivery date.

[0210] The order instruction (second order information 10b) for the second production base by the second order function of the main base can be carried out at a timing (after t2) after the start of transporting the common wire harness from the first production base to the second production base (t12).

[0211] By using the component manufacturing system having the above configuration, after confirming the quantity of the common wire harnesses produced at the first production base that can be obtained at the second production base, the content of the order instruction for the second production base can be appropriately adjusted according to the quantity.

[0212] The main base may include a main body part (10A) for obtaining temporary order information and a delivery part (10B) for obtaining confirmation information, and

[0213] The second production base can deliver the completed wire harness (wire harness PP) to the delivery location (customer's delivery location 42) via the delivery part.

[0214] By using the component manufacturing system having the above configuration, at the main base, the temporary order information and the confirmation information regarding the information on the order from the customer can be processed separately in independent parts or as independent functions. Therefore, the main part and the delivery part can be concentrated on only processing the functions respectively assigned to them, so that it is possible to avoid the complex processing caused by the mixing of generating the temporary order information and the confirmation information at different timings.

[0215] The component manufacturing system with the above configuration may also include an intermediate base (50) provided between the first production base and the second production base, which inspects the common wiring harness received from the first production base and transports the inspected common wiring harness to the second production base.

[0216] With the component manufacturing system having the above configuration, an inspection function is added to the intermediate base, so that the second production base can only obtain the common wiring harness that ensures the predetermined quality and can avoid complex processing.

[0217] Optional wiring harnesses can be produced at the second production base.

[0218] With the component manufacturing system having the above configuration, since the optional wiring harnesses are produced at the second production base where the common wiring harness and the optional wiring harnesses are combined with each other, it is not necessary to transport the optional wiring harnesses from another base to the second production base, further increasing the time margin from obtaining the confirmation information from the customer to the completion of the produced wiring harness.

[0219] According to an embodiment, the component manufacturing method can be used by a component manufacturer that manufactures a wiring harness as a vehicle component based on customer requirements.

[0220] Component manufacturing method

[0221] Using a main base, and a first production base and a second production base located in different regions from each other,

[0222] The main base provides the function of designing a common wiring harness (basic part B1) that is commonly used for multiple vehicle product numbers and multiple optional wiring harnesses (optional parts OP) that are different for each product number based on the planned information (first manufacturing specification information D1) from the customer,

[0223] The first production base provides the function of producing the common wiring harness based on the order instruction from the main base,

[0224] Arrange the second production base closer to the delivery location specified by the customer than the first production base, and

[0225] The second production base provides the functions of obtaining the common wiring harness from the first production base, producing optional wiring harnesses (optional parts OP) based on the order instruction from the main base, combining the common wiring harness with the optional wiring harnesses (optional parts OP), and delivering the completed wiring harness to the delivery location, where

[0226] The main base includes:

[0227] A first order step of determining the quantity of the common wiring harness to be produced based on the provisional order information and placing an order with the first production base (S12, S13);

[0228] A transportation step (S15) of transporting the common wire harness produced by the first production base to the second production base; and

[0229] A second order step (S22) of obtaining order confirmation information from a customer at a timing closer to the delivery date than the temporary order information and placing an order for the completed wire harness with the second production base based on the confirmation information.

[0230] By using the component manufacturing method with the above configuration, overstock of wire harnesses can be avoided. That is, the components produced at the first production base can be limited to common wire harnesses common to multiple product numbers, so that even if the common wire harnesses are manufactured in advance before confirming the required quantity of wire harnesses for each product number, the quantity of excess common wire harnesses generated that are not used for this delivery can be reduced to the level of fluctuations in the number of vehicles. Even if the first production base is located overseas, the second production base is also located at a position close to the delivery location, so that the time required to transport from the second production base to the delivery location is shortened, and it becomes easy to deliver the quantity of completed wire harnesses required by each product number customer before the delivery date without any shortage.

[0231] According to an embodiment, a component manufacturing system manufactures a wire harness as a vehicle component at a main base and a first production base and a second production base located in different regions from each other.

[0232] The main base includes:

[0233] Functions (basic part design function 12, optional part design function 13) of designing a common wire harness (basic part B1) commonly used for multiple vehicle product numbers and multiple optional wire harnesses (optional parts OP) different for each product number based on plan information (first manufacturing specification information D1) from a customer;

[0234] A function (order management server 14) of sending design information for producing the common wire harness to the first production base;

[0235] A first order function (order management server 14, first order information 10a) of determining the quantity of the common wire harness to be produced based on the temporary order information and placing an order with the first production base;

[0236] A function (order management server 14) of sending design information for producing the completed wire harness by combining the common wire harness and the optional wire harness to the second production base; and

[0237] A second order function (order management server 14, second order information 10b) of obtaining order confirmation information from a customer at a timing closer to the delivery date than the temporary order information and placing an order for the completed wire harness with the second production base based on the confirmation information.

[0238] By using the component manufacturing system with the above configuration, overstocking of wire harnesses can be avoided. That is, the components produced at the first production base can be limited to the common wire harnesses common to multiple product numbers, so that even if the common wire harnesses are manufactured in advance before the required quantities of the wire harnesses for each product number are confirmed, the quantity of the excess common wire harnesses not used for that delivery can be reduced to the extent of the fluctuations in the number of vehicles. Even if the first production base is located overseas, the second production base is also located close to the delivery location, so that the time required for transportation from the second production base to the delivery location is shortened, and it becomes easy to deliver the required quantity of the completed wire harnesses for each product number to the customer without any shortage before the delivery date.

[0239] By using the component manufacturing system and the component manufacturing method of the embodiment, even when a large number of common wire harnesses of product numbers are produced overseas and imported therefrom, overstocking of wire harnesses can be avoided, and it becomes easy for the component manufacturer to deliver the required quantity of wire harnesses to the customer without any shortage before the delivery date.

Claims

1. A component manufacturing system, which can be used by component manufacturers that manufacture wire harnesses as vehicle components based on customer requirements. The system includes: Main base; and a first production base and a second production base, which are located in different regions from each other, wherein the main base has a function of designing a basic part that is commonly used for multiple vehicle product numbers based on planned information from the customer and multiple optional parts that are different for each product number, and the optional parts are the remaining components after the basic part is excluded from the wire harnesses of each product number, the first production base has a function of producing the basic part based on an order instruction from the main base, the second production base is closer to a delivery location specified by the customer than the first production base, the second production base has a function of obtaining the basic part from the first production base, combining the basic part with the optional parts based on the order instruction from the main base, and delivering the completed wire harness to the delivery location, and the main base has a first order function of determining the quantity of the basic part to be produced based on temporary order information and placing an order with the first production base, and a second order function of obtaining order confirmation information from the customer at a timing closer to the delivery date than the temporary order information and placing an order for the completed wire harness with the second production base based on the confirmation information, the component manufacturing system further includes a design support device configured to: extract all components that commonly exist in the wire harnesses of all product numbers as main common components; determine the configuration of a sub-bundle of the basic part formed only by the extracted main common components; classify each remaining component among the components forming the wire harnesses of all product numbers after excluding all the extracted main common components as an optional component; obtain the predicted production quantity of the wire harness of each product number and the usage rate of each component, display a list of the components of each product number of the wire harness in tabular format on the screen, update the display content by rearranging the items of each product number in descending order of the predicted production quantity of each product number, update the display content by rearranging the content of each component on the screen in descending order of the usage rate, extract multiple sub-common components from among the large number of optional components displayed on the screen, and determine the configuration of sub-bundles of multiple additional parts formed only by the extracted sub-common components, where the multiple sub-common components are optional components whose usage rate is equal to or greater than a predetermined value, the usage rate of each component is calculated by the following formula: Usage rate = (Sum of the quantity of each component used for each product number) / (Total number of planned wire harnesses of all product numbers); and classify each remaining component among the optional components that is not selected as any sub-common component as an additional component, wherein the configuration of the wire harness of each product number is a combination of a sub-bundle of the basic part, sub-bundles of one or more additional parts, and additional components.

2. The component manufacturing system according to claim 1, wherein, The order instruction from the main base's second order function to the second production base is carried out at a timing after the start of the transportation of the basic part from the first production base to the second production base.

3. The component manufacturing system according to claim 1 or 2, wherein, The main base includes a main body part for obtaining the temporary order information and a delivery part for obtaining the confirmation information, and The second production base delivers the completed wire harness to the delivery location via the delivery section.

4. The component manufacturing system according to any one of claims 1 to 2, further comprising An intermediate base, which is provided between the first production base and the second production base, inspects the basic parts received from the first production base, and transports the inspected basic parts to the second production base.

5. The component manufacturing system according to any one of claims 1 to 2, wherein, The optional section is produced at the second production base.

6. A component manufacturing method, which can be used by component manufacturers that manufacture wire harnesses as vehicle components based on customer requirements. The method includes: A main base, a first production base, and a second production base located in different regions from each other are used; The main base provides functions of a basic section that is commonly designed for multiple vehicle product numbers based on planned information from the customer and multiple optional sections that are different for each product number. The optional sections are the remaining components after the basic section is excluded from the wire harnesses of each product number; The first production base provides the function of producing the basic section based on an order instruction from the main base; The second production base is arranged to be closer to the delivery location specified by the customer than the first production base; and The second production base provides the function of obtaining the basic section from the first production base, combining the basic section with the optional sections based on the order instruction from the main base, and delivering the completed wire harness to the delivery location; wherein the main base includes a first order step of determining the quantity of the basic section to be produced based on temporary order information and placing an order with the first production base; a transportation step of transporting the basic section produced by the first production base to the second production base, and a second order step of obtaining order confirmation information from the customer at a timing closer to the delivery date than the temporary order information and placing an order for the completed wire harness with the second production base based on the confirmation information; The component manufacturing method further includes a design support step, which: Extracts all components that commonly exist in the wire harnesses of all product numbers as main common components; Determines the configuration of the sub-harness of the basic section formed only by the extracted main common components; Classifies each of the remaining components among the components forming the wire harnesses of all product numbers after excluding all the extracted main common components as optional components; Obtains the predicted production quantity of the wire harness of each product number and the usage rate of each component, displays a list of the components of each product number of the wire harness in a table format on the screen, updates the display content by rearranging the items of each product number in descending order of the predicted production quantity of each product number, updates the display content by rearranging the content of each component on the screen in descending order of the usage rate, extracts multiple sub-common components from the large number of optional components displayed on the screen, and determines the configuration of the sub-harnesses of multiple additional sections formed only by the extracted sub-common components. The multiple sub-common components are optional components whose usage rate is equal to or greater than a predetermined value; The usage rate of each component is calculated by the following formula: Usage rate = (sum of the usage quantity of each component of each product number) / (quantity of the total planned wire harnesses of all product numbers); and Classifies each of the remaining components among the optional components that are not selected as any sub-common component as additional components; wherein the configuration of the wire harness of each product number is a combination of the sub-harness of the basic section, the sub-harnesses of one or more additional sections, and additional components.

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