Parts inventory management system and parts inventory management method

Abstract

This system provides a parts inventory management system that minimizes the risk of running out of assembly parts, even when it becomes necessary to reduce the number of assembly parts stocked within the parts assembly process on an assembly line. [Solution] The parts inventory management system comprises an image display device and an application program that displays on the monitor section of the image display device the number of assembled parts (batteries) to be assembled to a workpiece that has reached the parts assembly position, among a plurality of workpieces (assembly partner members) that are intermittently fed along the workpiece transport path. By executing the application program, the system processes the number of assembled parts displayed on the monitor section to decrease each time the assembly partner member reaches a count position that is a predetermined number of feeds prior to the parts assembly position.

Description

Technical Field

[0001] The present invention relates to a parts inventory management system and a supervision method.

Background Art

[0002] For example, in an assembly line where a plurality of assembly processes for assembling another work (assembly part) to a work (assembly mating member) intermittently fed on a work conveyance path are provided along the work conveyance path, if the assembly parts run out of stock at just one of the assembly processes, there is a risk that the entire line will stop. Therefore, in the assembly line as described above, it is necessary to strictly manage the stock quantity of the assembly parts in each assembly process. For example, when the assembly parts are large parts whose stock quantity can be grasped at a glance, the assembly worker visually checks the stock quantity of the assembly parts on the parts shelf in the process, and when the stock quantity reaches or falls below a predetermined value, issues a supply request (supply instruction) for the assembly parts to the supply worker in charge of the supply work of the assembly parts.

[0003] In each assembly process provided in the assembly line as described above, for example, a flow rack as described in Patent Document 1 below is often used as a parts shelf for storing (stocking) the assembly parts. The above-mentioned flow rack is a rack configured such that the shelf board slopes downward from the back side (supply port side) toward the front side (takeout port side), and the parts placed on the shelf board move to the front side by their own weight. It has the advantage that it can easily and smoothly manage the stock quantity of the parts, supply and take out the parts, etc.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Incidentally, in the assembly line described above, there may be an assembly process in which one of two types of assembly parts is selectively attached to a workpiece (assembly mating component) being transported along the workpiece transport path. In such an assembly process, it is necessary to stock both types of assembly parts. In this case, if the goal is to maintain the same stock quantity for each of the two types of assembly parts as when there is only one type of assembly part, especially if the assembly parts are large, it will be necessary to expand the parts storage space within the process by adding or enlarging parts shelves, such as those made up of the aforementioned flow racks. However, this may encroach on the space occupied by adjacent assembly processes and the passageways within the line, which is undesirable.

[0006] If we cannot expand parts storage space by adding more parts shelves, the inventory levels for each of the two types of assembly parts will have to be lower than when there is only one type of assembly part. In this case, it will be necessary to increase the frequency of supplying parts to the shelves, which raises concerns about a significant increase in the workload of the supply workers. Furthermore, it is rare for each assembly process to have a dedicated supply worker, and supply workers typically handle parts supply for multiple assembly processes. Therefore, even if an assembly worker requests the supply of assembly parts, they may not receive the parts immediately. Consequently, if we are forced to reduce the inventory levels of assembly parts in the assembly process as described above, there is a concern that the risk of running out of assembly parts will increase.

[0007] In view of the above circumstances, the present invention aims to provide a technical means that makes it possible to reduce as much as possible the risk of running out of assembly parts, even when it is necessary to reduce the number of assembly parts stocked in the parts assembly process provided in the assembly line. [Means for solving the problem]

[0008] The parts inventory management system according to the present invention, which was devised to achieve the above objectives, Image display device and The image display device includes an application program that displays the number of assembly parts in stock that are to be assembled to the mating member that has reached the assembly position among multiple workpieces being intermittently fed along the workpiece transport path. The application program is characterized in that the inventory count of the assembly parts displayed on the monitor unit decreases each time the mating member reaches a count position that is a predetermined number of feeds prior to the part assembly position.

[0009] In the parts inventory management system according to the present invention, the application program is designed so that the number of assembled parts in stock displayed on the monitor of the image display device decreases each time the mating member reaches a count position that is a predetermined number of feeds prior to the part assembly position. In other words, the number of assembled parts in stock (stock status) displayed on the monitor of the image display device in the parts inventory management system according to the present invention differs from the stock status of assembled parts on the parts shelves in the actual assembly process, and represents the stock status at the aforementioned count position. In this case, by looking at the monitor of the image display device, it becomes possible to predict (understand) the number of assembled parts in stock when the mating member that has reached the count position is fed a predetermined number of more times and reaches the part assembly position, making it possible to supply assembled parts at an appropriate timing to prevent stockouts. As a result, even in cases where it is necessary to reduce the number of assembled parts stocked in the assembly process provided in the assembly line, the risk of running out of assembled parts can be reduced as much as possible.

[0010] In a parts inventory management system having the above configuration, it is preferable that the application program is designed to display a supply instruction for assembly parts on the monitor unit when the number of assembly parts in stock displayed on the monitor unit falls below a predetermined value. This allows the assembly parts supplier to start and execute the assembly parts supply operation at the appropriate time.

[0011] Furthermore, in a parts inventory management system having the above configuration, it is preferable that the image display device is a mobile terminal with a touch panel display as the monitor. In this way, parts supply workers can always carry the image display device and check the inventory status of parts shelves at any time, thereby improving the efficiency of parts supply operations.

[0012] The above objective is the parts inventory management method according to the second invention of this application, specifically, A method for managing the inventory of assembly parts in a parts shelf that are taken from the parts shelf and assembled to a component to be assembled when it reaches the component assembly position among multiple workpieces that are intermittently fed along a workpiece transport path, This can also be achieved by a parts inventory management method characterized by supplying assembly parts to a parts shelf based on the number of assembly parts in stock displayed on the monitor of an image display device each time the assembly target member reaches a position a predetermined number of feeds back from the assembly position. [Effects of the Invention]

[0013] Based on the above, according to the present invention, even when it is necessary to reduce the number of assembled parts stocked in the parts assembly process of an assembly line, it is possible to reduce as much as possible the risk of running out of assembled parts. [Brief explanation of the drawing]

[0014] [Figure 1] (a) Figure is a schematic diagram of a portion of an assembly line in which a parts inventory management system according to an embodiment of the present invention is used, and (b) Figure is a schematic diagram showing an example of the arrangement of workpieces transported within the assembly line. [Figure 2] This is a schematic diagram of the battery assembly process provided on the assembly line shown in Figure 1(a). [Figure 3] This is a schematic diagram of a parts inventory management system according to an embodiment of the present invention. [Figure 4] This is a magnified view of a portion of the image display device when the image showing the inventory status of assembled parts changes from the state shown in Figure 3. [Figure 5] An enlarged view of the main part of an image display device when an image showing the inventory status of assembled parts changes from the state shown in FIG. 3. FIG. (a) shows an example of a state where it is necessary to supply one of two types of assembled parts to a parts shelf. FIG. (b) shows an example of a state where it is necessary to supply the other of two types of assembled parts to a parts shelf. FIG. (c) shows an example of a state where it is necessary to supply both of two types of assembled parts to a parts shelf.

Embodiments for Carrying Out the Invention

[0015] Hereinafter, embodiments of the present invention will be described based on the drawings.

[0016] The parts inventory management system according to an embodiment of the present invention is used, for example, to appropriately manage the inventory of assembled parts in a parts assembly process that constitutes an assembly line 1 conceptually shown in FIG. 1(a) (carry out the supply operation of assembled parts to a parts shelf provided in the process at an appropriate timing and prevent stockouts of assembled parts in the above parts shelf as much as possible). The assembly line 1 shown in FIG. 1 has a plurality of parts assembly processes A1, A2, A3... installed along a work conveyance path R along which a plurality of workpieces (workpieces to be assembled with parts, hereinafter referred to as "assembly mating members") W are intermittently fed at a predetermined interval, and predetermined parts are assembled to the assembly mating members in each of the parts assembly processes A1, A2, A3...

[0017] As a specific example of the assembly line 1, a complete vehicle assembly line for an automobile in which the above assembly mating member W is an automobile chassis can be cited. As shown in FIG. 1(b), on the assembly line 1, vehicle chassis W1 for a hybrid vehicle (HEV) equipped with a large-capacity driving battery, vehicle chassis W2 for a hybrid vehicle equipped with a small-capacity driving battery, and vehicle chassis W3 for a gasoline vehicle are input in the order of received orders. Therefore, three types of vehicle chassis W1 to W3 are randomly arranged on the work conveyance path R provided in the assembly line 1.

[0018] Here, the component assembly process A2 provided on the assembly line 1 is defined as a battery assembly process for assembling a traveling battery that supplies power to an electric motor as a drive source to the vehicle body. In this assembly process A2, as conceptually shown in FIG. 2, traveling batteries B1 and B2 are respectively assembled to the vehicle bodies W1 and W2 for hybrid vehicles by the assembly worker 3. Therefore, in the component shelf 2 within the assembly process A2, two types of traveling batteries B1 and B2 with different capacities are stocked (accommodated). Since both the traveling batteries B1 and B2 are large components with a maximum length of nearly 1 m and a weight of dozens of kg, there is a limit to the number that can be accommodated in the component shelf 2 within the assembly process A2. The component shelf 2 in the illustrated example has an accommodation space that can accommodate a maximum of 9 batteries B1 and an accommodation space that can accommodate a maximum of 10 batteries B2, which are somewhat more compact than the battery B1. Note that neither of the traveling batteries B1 and B2 is assembled to the vehicle body W3 for gasoline vehicles that do not require a traveling battery.

[0019] Although detailed illustration is omitted, as the component shelf 2, a so-called flow shelf is used in which the shelf board slopes downward from the component supply port (rear surface) side toward the component take-out port (front surface) side, and when components are placed on the shelf board, the components automatically slide to the front surface side due to their own weight. In this case, the assembly worker 3 takes out the battery B1 (or B2) accommodated in the component shelf 2 on the front surface side of the component shelf 2 and performs an assembly operation of assembling the taken-out battery B1 (or B2) to the vehicle body W1 (or W2). As the accommodation space in the component shelf 2 becomes vacant due to this assembly operation, a battery supply operation to the component shelf 2 by a supply worker 4 different from the assembly worker 3 is performed on the rear surface side of the component shelf 2.

[0020] In the present embodiment, the supply operation of the batteries B1 and B2 by the supply worker 4 is completed by transporting two pallets each loaded with 4 batteries to a position near the component shelf 2 using an electric cart or the like and then transferring the batteries loaded on the pallets to the component shelf 2 as shown in FIG. 2. In this case, the supply worker 4 • The first pair consists of two pallets, each loaded with four B1 batteries, connected together. • A second pair consisting of two pallets, each loaded with four Battery B2s, connected together, or • Transport one of a third pair, which consists of one pallet loaded with four batteries B1 and another pallet loaded with four batteries B2. Which pair is transported depends on the availability of storage space for batteries B1 and B2 in the parts shelf 2, and in this embodiment, the parts inventory management system 10, described below, indicates which pair to transport.

[0021] The following describes the parts inventory management system of this embodiment.

[0022] As shown in Figure 3, the parts inventory management system 10 includes an image display device 11 and an application program (not shown) stored in the internal storage of the image display device 11 that displays the inventory status of batteries B1 and B2, which are assembled to chassis W1 and W2 respectively in the battery assembly process 2, on the monitor unit 12 of the image display device 11. In this embodiment, the image display device 11 is a mobile terminal with a touch panel display for the monitor unit 12, and is carried by the replenishment worker 4 who is in charge of supplying batteries B1 and B2.

[0023] The above application program is displayed on the monitor unit 12. • Image 13 of the workpiece column corresponding to the column of workpieces W (chassis W1~W3) actually being transported along the workpiece transport path R of assembly line 1. • An assembly position identification pointer 14 indicates the location (installation position) where the battery assembly process A2 is performed on the workpiece transport path R. • A count position identification pointer 15 indicates a position (count position) that is a predetermined number of workpiece feeds backward from the position where the battery assembly process A2 is performed (the position pointed to by the assembly position identification pointer 14) on the workpiece transport path R, and • Inventory status of batteries B1 and B2 in parts shelf 2 of battery assembly process A2. It is designed to display at all times. The position of the count position identifying pointer 15 can be changed as needed, and in this embodiment, where the monitor unit 12 is a touch panel display, the position of the pointer 15 can be changed by tracing the surface of the monitor unit 12.

[0024] Although not shown in the diagram, in the work sequence image 13, different colors are used for the symbols (in this case, rectangular symbols) representing chassis W1, W2, and W3 so that the replacement worker 4 can easily identify the transport order of chassis W1 to W3 within the assembly line 1. The work sequence image 13 is updated as needed based on information output from the main production management system (not shown in the diagram).

[0025] The "inventory status" displayed on the monitor unit 12 can be understood by switching between filled-in and blank rectangular symbols 16A and 16B, which are displayed in the same number as the number of batteries B1 and B2 that can be stored in the parts shelf 2 in the battery assembly process A2. In this embodiment, a parts shelf 2 that can store a maximum of 9 batteries B1 and a maximum of 10 batteries B2 is used, so a total of 9 rectangular symbols 16A corresponding to batteries B1 and a total of 10 rectangular symbols 16B corresponding to batteries B2 are always displayed. When the inventory of batteries B1 and B2 in the parts shelf 2 is at its maximum, such as when the assembly line 1 starts up, all 9 rectangular symbols 16A and all 10 rectangular symbols 16B are displayed filled in, as shown in Figure 3. On the other hand, although not shown in the illustration, when the inventory of batteries B1 and B2 in the parts shelf 2 is zero, all rectangular symbols 16A and 16B are displayed blank.

[0026] As assembly line 1 becomes operational and battery assembly work is carried out in battery assembly process A2, the number of batteries B1 and B2 in stock in parts shelf 2 decreases. As a result, the number of filled rectangular symbols 16A and 16B displayed on the monitor unit 12 decreases, and the number of open rectangular symbols 16A and 16B increases. When the number of open rectangular symbols 16A and 16B exceeds a predetermined value, or when other conditions are met, a message indicating that either or both of batteries B1 and B2 should be supplied to parts shelf 2 is displayed in the message display area 18 of the monitor unit 12.

[0027] In this embodiment, as described above, the supply worker 4 carries one of the first pair, second pair, or third pair shown in Figure 2 to supply the battery to the parts shelf 2. (1) When the number of either the white square symbol 16A or 16B displayed becomes 8, (2) When the number of displays of either the white rectangular symbol 16A or 16B is 4 or more and 7 or less, and the number of displays of the other symbol becomes 4, The above supply instruction message will be displayed.

[0028] For example, the case shown in Figure 5(a) is an example of (1) above. That is, in Figure 5(a), there are 8 white rectangular symbols 16A displayed (in the illustrated example, there are 2 white rectangular symbols 16B displayed). In this case, a message indicating "Battery B1 supply required" is displayed in the message display area 18 of the monitor unit 12. Upon seeing this message, the supply worker 4 carries the first pair described above and supplies (replenishes) all 8 batteries B1 to the parts shelf 2.

[0029] Furthermore, the case shown in Figure 5(b) is another example of (1) above. That is, in Figure 5(b), the number of white rectangular symbols 16B displayed is 8 (in the illustrated example, the number of white rectangular symbols 16A displayed at this time is 2). In this case, a message indicating "Battery B2 supply required" is displayed in the message display area 18 of the monitor unit 12. Upon seeing this message, the supply worker 4 carries the second pair described above and supplies all 8 batteries B2 to the parts shelf 2.

[0030] Furthermore, the case shown in Figure 5(c) is an example of (2) above. That is, in Figure 5(c), there are 5 white rectangular symbols 16A and 4 white rectangular symbols 16B. In this case, a message indicating "Supply of batteries B1 and B2 is required" is displayed in the message display area 18 of the monitor unit 12. Upon seeing this message, the supply worker 4 carries the third pair and supplies all 4 batteries B1 and 4 batteries B2 to the parts shelf 2.

[0031] The display conditions and timing of the supply instruction message were set as described above to ensure that all batteries loaded on the pallet are supplied to the parts shelf 2 without waste, and to prevent batteries that have been brought close to the parts shelf 2 from being taken back (saving wasted labor for the supply worker 4). In other words, for example, if the supply worker 4 performs the battery supply work with five white rectangular symbols 16A and one white rectangular symbol 16B displayed, as shown in Figure 4, there is a possibility that three batteries B1 will not be supplied to the parts shelf 2 when the first pair is carried, and three batteries B2 will not be supplied to the parts shelf 2 when the third pair is carried.

[0032] As described above, once the supply worker 4 has completed the supply of batteries B1 and B2 to the parts shelf 2, the supply worker 4 presses the parts supply buttons 17A and 17B (see Figure 3) displayed on the monitor unit 12. The parts supply buttons 17A and 17B are pressed when the supply of batteries B1 and B2 is complete, and when each button is pressed, the corresponding rectangular symbols 16A and 16B change from white to filled in.

[0033] In this embodiment, as shown in Figures 5(a) to (c), when it becomes necessary to supply batteries to the parts shelf 2, in addition to the message display in the message display area 18, the outlines of the rectangular symbols corresponding to the batteries that need to be supplied are enclosed with thick lines. Specifically, in the example shown in Figure 5(a) where eight batteries B1 need to be supplied, the outlines of No. 2 to No. 9 of rectangular symbol 16A are enclosed with thick lines; in the example shown in Figure 5(b) where eight batteries B2 need to be supplied, the outlines of No. 3 to No. 10 of rectangular symbol 16B are enclosed with thick lines; and in the example shown in Figure 5(c) where four batteries B1 and four batteries B2 need to be supplied, the outlines of No. 6 to No. 9 of rectangular symbol 16A are enclosed with thick lines, as well as the outlines of No. 7 to No. 10 of rectangular symbol 16B are enclosed with thick lines. This provides further attention to the supply worker 4.

[0034] In the parts inventory management system 10 of this embodiment, the application program is designed so that the inventory count of assembly parts (batteries B1, B2) displayed on the monitor unit 12 of the image display device 11 is reduced each time the chassis W1, W2, which are the assembly mating members, reach a count position (the position indicated by the count position identification pointer 15) that is a predetermined number of feeds back from the execution position of assembly process A2 (the position indicated by the assembly position identification pointer 14).

[0035] In other words, the number of batteries B1 and B2 in stock (the number of filled square frames 16A and 16B corresponding to them) displayed on the monitor unit 12 of the image display device 11 differs from the actual number of batteries B1 and B2 in stock (stock status) on the parts shelf 2 (parts shelf 2 of the battery assembly process A2), and represents the number of batteries in stock at the position indicated by the count position identification pointer 15 on the assembly line 1. In this case, by looking at the monitor unit 12 of the image display device 11, it becomes possible to predict the number of batteries B1 and B2 in stock when the chassis, which is the assembly mating component, has been sent a predetermined number of more times after reaching the execution position of assembly process A2 (the position indicated by the assembly position identification pointer 14), which is the position to be assembled. Therefore, it becomes possible to perform the supply operation of batteries B1 and B2 at an appropriate timing to prevent running out of batteries B1 and B2.

[0036] Furthermore, in the parts inventory management system of this embodiment, when the inventory count of batteries B1 and B2 displayed on the monitor unit 12 reaches a predetermined value, a message indicating that batteries B1 and B2 should be supplied is displayed on the monitor unit 12, so that the supply worker 4 can start and execute the supply work of batteries B1 and B2 at the appropriate time.

[0037] Based on the above, the parts inventory management system according to the present invention can minimize the risk of running out of parts, even in cases where the battery assembly process 2 on the assembly line 1 requires selectively attaching one of the two types of batteries B1 and B2 to the chassis as the assembly mating member, thus necessitating a reduction in the inventory of each battery B1 and B2 compared to the case where there is only one type of battery as an assembly part.

[0038] Although one embodiment of the present invention has been described above, the embodiments of the present invention are not limited thereto.

[0039] For example, in the embodiments described above, we described the use of the parts inventory management system according to the present invention when managing parts inventory in an assembly process in which one of two types of assembly parts is selectively assembled to a mating member. However, the parts inventory management system according to the present invention can also be preferably used when managing parts inventory for one type of assembly part. [Explanation of Symbols]

[0040] 1 Assembly Line 2 Parts shelves 3. Assembly worker 4. Supply Workers 10. Parts Inventory Management System 11 Image display device 12 Monitor section 14. Assembly position identification pointer 15 Count position pointer 16A, 16B symbols A1, A2, A3 parts assembly process B1, B2 Battery (Assembly Part) R Work transport path Double job W1 Chassis (Mating component) W2 chassis (matting component) W3 chassis

Claims

1. Image display device and The monitor section of the image display device includes an application program that displays the inventory status of assembly parts to be assembled to the assembly mating member that has reached the assembly position among a plurality of workpieces that are intermittently fed along the workpiece transport path. The parts inventory management system is characterized in that the application program is designed to reduce the inventory quantity of the assembled parts and display it on the monitor unit each time the mating member reaches a count position that is a predetermined number of feeds prior to the part assembly position.

2. The parts inventory management system according to claim 1, wherein the application program is designed to display a supply instruction for the assembly parts on the monitor unit when the number of assembly parts in stock displayed on the monitor unit falls below a predetermined value.

3. A method for managing the inventory of assembly parts in a parts shelf that are taken from the parts shelf and assembled to a component to be assembled at a component assembly position among multiple workpieces that are intermittently fed along a workpiece transport path, A parts inventory management method characterized by replenishing the parts shelf with the assembly parts each time the assembly target member reaches a position a predetermined number of feeds back from the assembly position, based on the inventory count in the parts shelf displayed in a reduced manner on the monitor of an image display device.

Images