Mixed-model production system

Abstract

To provide a mixed-model production system that can suppress cost increases. [Solution] The mixed-model production system according to this disclosure is a mixed-model production system that mixes multiple types of workpieces and processes the workpieces using multiple processing stations, wherein multiple processing tools for processing multiple types of workpieces are provided at multiple processing stations, and the number of workpieces processed by the processing tools is less than the number of workpieces processed when multiple processing stations are provided with processing tools for processing one type of workpiece.

Description

Technical Field

[0001] The present disclosure relates to a mixed-flow production system.

Background Art

[0002] In recent years, technologies for processing multiple types of workpieces on a production line have been disclosed. For example, Patent Document 1 discloses a technology related to a conveyance system including a first processing line for performing a first processing on workpieces of multiple models and a second processing line for performing a second processing. The conveyance system according to Patent Document 1 includes a plurality of first processing machines and second processing machines in each of the first and second processing lines. Each processing machine is set with a corresponding model of workpiece. The first loading loader loads the workpiece from the first delivery device into the first processing machine, and the first unloading loader unloads the workpiece from the first processing machine to the second delivery device. The same applies to the second processing line.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the process of the conveyance system according to Patent Document 1, the first processing line and the second processing line are connected in series via a loading loader, a conveyance loader, and a delivery device. Therefore, when the loading loader and the unloading loader are transporting workpieces of a certain model, workpieces of other models are in a waiting state. This may occur, for example, when the processing at the processing machine is completed and the workpiece is waiting to move, or when waiting to move from the delivery device to the processing machine. In order to avoid the occurrence of waiting time in such cases, it is necessary to duplicate the conveyance system. However, duplicating the system leads to an increase in cost.

[0005] This disclosure is made to solve these problems and aims to provide a mixed-model production system that can suppress cost increases. [Means for solving the problem]

[0006] The mixed-model production system according to this disclosure is a mixed-model production system that mixes multiple types of workpieces and processes the workpieces using multiple processing stations, wherein the multiple processing stations are equipped with multiple processing tools for processing the multiple types of workpieces, and the number of workpieces processed by the processing tools is less than the number of workpieces processed when the multiple processing stations are equipped with processing tools for processing one type of workpiece. In the mixed-model production system according to this disclosure, the number of processing tools for processing a workpiece at a processing station can be reduced by lowering the production capacity required for processing a predetermined type of workpiece. Therefore, a single processing station can be equipped with processing tools for processing multiple types of workpieces. As a result, the mixed-model production system according to this disclosure can suppress cost increases by avoiding the duplication of systems. [Effects of the Invention]

[0007] This disclosure makes it possible to provide a mixed-model production system that can suppress cost increases. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a schematic diagram showing an example of a mixed-flow production system 1 according to this disclosure. [Figure 2] Figure 2 is a flowchart showing an example of the operation of the mixed-model production system 1. [Figure 3] Figure 3 is a schematic diagram showing an example of a system with multiple lines in a mixed-model production line. [Modes for carrying out the invention]

[0009] Embodiments of the present disclosure will be described below with reference to the drawings. Figure 1 is a schematic diagram showing an example of a mixed-model production system 1 according to the present disclosure. The mixed-model production system 1 is a system for processing multiple types of workpieces in a mixed flow. In Figure 1, the arrows indicate the direction of workpiece transport. There may be two types of workpieces, or three or more types. The workpieces may be, for example, automotive parts. Automotive parts include stators, rotors, motor shafts, etc.

[0010] Mixed-model production system 1 may be a system that produces the same automobile parts for multiple different vehicle models in a mixed-model system, or a system that produces multiple automobile parts for the same vehicle model in a mixed-model system, or a system that produces multiple automobile parts for multiple different vehicle models in a mixed-model system. Hereafter, we will continue the explanation assuming that mixed-model production system 1 is a system that produces the same automobile parts for multiple different vehicle models in a mixed-model system.

[0011] In this embodiment, the processing may be cutting, painting, screwing, welding, or any other type of processing. The processing of the workpiece may be performed by a robot or the like, or by a worker. In other words, the processing in this embodiment may be automated.

[0012] The mixed-flow production system 1 may flow the mixed-flow workpieces irregularly or regularly. In other words, the mixed-flow production system 1 may flow the mixed-flow workpieces randomly or not. When the mixed-flow workpieces are flowed irregularly, the production method by the mixed-flow production system 1 can be called mixed-flow random production.

[0013] The mixed-model production system 1 comprises a first processing station 2 and a second processing station 3. In other words, the mixed-model production system 1 is a system that processes workpieces using multiple processing stations. Here, a processing station refers to equipment or space provided for processing workpieces. In the mixed-model production system 1, each processing station processes workpieces for vehicle type A and workpieces for vehicle type B. The mixed-model production system 1 may have three or more processing stations. A processing station may also be called a work station.

[0014] The first processing station 2 is a processing station that performs the first processing on workpieces as they move along the line. Similarly, the second processing station 3 is a processing station that performs the second processing on workpieces as they move along the line. In particular, the second processing station 3 is a processing station that performs the second processing on workpieces that have already undergone the first processing by the first processing station 2.

[0015] The first processing station 2 is equipped with a first processing tool 4. The second processing station 3 is equipped with a second processing tool 5. Specifically, the first processing station 2 is equipped with a first processing tool 4a for performing the first processing on a workpiece for vehicle type A, and a first processing tool 4b for performing the first processing on a workpiece for vehicle type B. The second processing station 3 is equipped with a second processing tool 5a for performing the second processing on a workpiece for vehicle type A, and a second processing tool 5b for performing the second processing on a workpiece for vehicle type B. A processing tool is a tool used when processing a workpiece. A processing tool may be an end effector on a robot arm, or it may be a tool used by an operator when processing manually.

[0016] In other words, the first processing station 2 and the second processing station 3 are each equipped with processing tools capable of processing multiple types of workpieces. The number of processing tools in each processing station may be two or three or more. In addition, some processing stations may be equipped with one processing tool. In this case, the processing tool shall be capable of processing multiple types of workpieces.

[0017] In the mixed-model production system 1 according to this embodiment, the first processing tool 4a for vehicle type A is used only for the first processing of workpieces for vehicle type A. That is, the first processing tool 4a for vehicle type A cannot be used to perform the first processing on workpieces for vehicle type B. Similarly, the first processing tool 4b for vehicle type B cannot be used to perform the first processing on workpieces for vehicle type A. Furthermore, the second processing tool 5a for vehicle type A cannot be used to perform the second processing on workpieces for vehicle type B, and the second processing tool 5b for vehicle type B cannot be used to perform the second processing on workpieces for vehicle type A.

[0018] The first machining tool 4a for vehicle type A performs one or more machining operations on a workpiece for vehicle type A. In other words, the first machining tool 4a for vehicle type A performs a predetermined number of machining operations on a workpiece for vehicle type A. Similarly, the first machining tool 4b for vehicle type B performs a predetermined number of machining operations on a workpiece for vehicle type B. The same applies to the second machining tool 5a for vehicle type A and the second machining tool 5b for vehicle type B.

[0019] The number of times a workpiece for vehicle type A or vehicle type B is processed by a processing tool at the first processing station 2 and the second processing station 3 is less than the number of times a single workpiece is processed at a single processing station. In other words, the number of times a workpiece is processed by a predetermined processing tool at a processing station equipped with multiple processing tools for processing multiple types of workpieces is less than the number of times a workpiece is processed at that processing station equipped with a processing tool for processing only that workpiece.

[0020] For example, the number of processes performed by the first processing tool 4a for vehicle type A at the first processing station 2 is less than the number of processes performed by the processing tool when only the first processing tool 4a for vehicle type A is provided at the first processing station 2. Similarly, the number of processes performed by the first processing tool 4b for vehicle type B is less than the number of processes performed by the processing tool when only the first processing tool 4b for vehicle type B is provided at the first processing station 2. The same applies to the second processing station 3.

[0021] The number of processes by each processing tool may be half, one-third, or one-fourth of the number of processes in the case where the processing station is provided with a processing tool for processing one type of workpiece. That is, the number of processes by each processing tool may be less than or equal to half of the number of processes in the case where the processing station is provided with a processing tool for processing one type of workpiece. The number of processes by each processing tool may be the number obtained by dividing the number of processes in the case where each processing station is provided with a processing tool for processing one type of workpiece by the number of types of processing tools.

[0022] When the processing station is provided with a processing tool for processing one type of workpiece, and assuming that the processing tool performs processing for one workpiece, at the first processing station 2 and the second processing station 3 of the mixed-flow production system 1, each may perform half of the processing for the workpiece.

[0023] For example, when a processing station provides a processing tool for processing one type of workpiece, assume that the number of processing operations for one workpiece for vehicle type A and vehicle type B by the processing tool is 48. In this case, the number of processing operations for the workpiece by the first processing tool 4a for vehicle type A and the first processing tool 4b for vehicle type B may each be half, i.e., 24. Also, the number of processing operations for each of the second processing tool 5a for vehicle type A and the second processing tool 5b for vehicle type B may also be 24. That is, the two processing stations of the mixed-flow production system 1 may perform the processing at one processing station when the processing station provides a processing tool for processing one type of workpiece.

[0024] The mixed-flow production system 1 may include a lifter not shown in FIG. 1. The lifter is a device that raises the workpiece when the transported workpiece arrives at the processing station. That is, the lifter is a device that lifts the workpiece to the height at which the processing tool performs the processing of the workpiece. The lifter may have an indexing function for adjusting the position and orientation of the workpiece. At this time, the lifter may receive the vehicle type information determined by a vehicle type detection sensor (not shown). For example, in the first processing station 2, when a workpiece for vehicle type A is carried in, the lifter in the first processing station 2 may lift or rotate the workpiece to move the workpiece to the processing position of the first processing tool 4a for vehicle type A. That is, the indexing position by the lifter may be the processing position of the processing tool.

[0025] Next, the operation flow of the mixed-flow production system 1 will be described. FIG. 2 is a flowchart showing an example of the operation of the mixed-flow production system 1. First, the mixed-flow production system 1 carries in the workpiece (step S1). Next, the mixed-flow production system 1 performs the first processing on the workpiece at a predetermined number of operations in the first processing station 2 (step S2). Thereafter, the mixed-flow production system 1 performs the second processing on the workpiece at a predetermined number of operations in the second processing station 3 (step S3). Thereafter, the mixed-flow production system 1 carries out the processed workpiece (step S4).

[0026] Thus, the mixed-model production system 1 according to this embodiment can process multiple types of workpieces in a mixed flow without requiring the system to be duplicated, thereby suppressing cost increases. The effects of the mixed-model production system 1 will be described in detail below.

[0027] In related technologies, the system structure of a mixed-model production line is such that one processing station processes only one type of workpiece. That is, if multiple types of workpieces are mixed and brought into a processing station, and the type of workpiece supplied does not match the type of workpiece handled by that processing station, the workpiece cannot be processed at that station. In this case, a waiting time occurs for the workpiece. Therefore, with such a system structure, there is a risk that the target cycle time (CT) will not be achieved.

[0028] To solve this problem, one possible solution is to create a dual-line system. An example of a dual-line system is shown in the diagram. Figure 3 is a schematic diagram showing an example of a dual-line system in a mixed-model production line. The mixed-model production system in Figure 3 is a system that produces the same automobile parts for multiple different vehicle models in a mixed-model production system. In Figure 3, a vehicle model detection sensor (not shown) determines whether a transported workpiece is for vehicle model A or vehicle model B. The workpiece is then distributed to either a processing station for vehicle model A or a processing station for vehicle model B. Each processing station processes one type of workpiece. By creating a dual-line system, there is no waiting time for workpieces, so the target CT can be met. On the other hand, there is a concern that creating a dual-line system will increase costs.

[0029] The mixed-model production system 1 according to this embodiment can process multiple types of workpieces without requiring the system to be duplicated, thereby suppressing cost increases. Furthermore, the mixed-model production system 1 can satisfy the target CT (Cooling Time). Specifically, the mixed-model production system 1 is equipped with multiple processing tools for processing multiple types of workpieces at multiple processing stations. Therefore, regardless of the type of workpiece brought in, it can be processed using the processing tool corresponding to that workpiece. Consequently, the mixed-model production system 1 can reduce workpiece waiting times.

[0030] The number of workpieces processed at the processing station of the mixed-model production system 1 according to this embodiment is less than the number of workpieces processed when the processing station processes only one type of workpiece. In other words, the production capacity required of the processing station of the mixed-model production system 1 is lower than when the processing station processes only one type of workpiece. Therefore, the number of processing tools for a given type of workpiece at the processing station of the mixed-model production system 1 is less than the number of processing tools when the processing station processes only one type of workpiece. As a result, the space required for processing tools for a given type of workpiece at the processing station is reduced, and the reduced space can be used to place processing tools for other types of workpieces.

[0031] This allows the mixed-model production system 1 to have multiple types of processing tools in a single processing station. Therefore, the mixed-model production system 1 can suppress cost increases by avoiding the need for dual-line systems.

[0032] This disclosure is not limited to the embodiments described above, and can be modified as appropriate without departing from its spirit. For example, the mixed-model production system according to this disclosure may use a single-piece flow system or a batch production system. Furthermore, the mixed-model production system according to this disclosure may be used for the production of electronic equipment or for the production of industrial machinery. [Explanation of Symbols]

[0033] 1. Mixed-model production system, 2. First processing station, 3. Second processing station, 4. First processing tool, 5. Second processing tool

Claims

[Claim 1] A mixed-flow production system that mixes multiple types of workpieces and processes them using multiple processing stations, Multiple processing stations are provided with multiple processing tools for processing multiple types of workpieces, and the number of workpieces processed by the processing tools is less than the number of workpieces processed when each of the multiple processing stations is provided with a processing tool for processing one type of workpiece. Mixed-model production system.

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