JP5186193B2 - Flexible production system - Google Patents

Description

  The present invention relates to a flexible production system using a cell production method.

  In recent years, instead of a so-called conveyor line production system that is suitable for mass production, which is one of product production systems, flexible production systems that can flexibly cope with increase / decrease in production volume and multi-variable production are gradually expanding. In a conventional line production system, a plurality of stations are provided along a conveyor line, and workers, production equipment, tools, parts, members, and the like are arranged in each station. A workpiece that is the basis of a product is sequentially conveyed between stations by a conveyor line, and is subjected to a predetermined work process such as assembly of parts at each station and shipped as a product.

  The above-mentioned conveyor line production method usually requires a large investment in equipment such as dedicated conveyor equipment, and large-scale line reorganization and equipment modification are required to respond to product model changes and production volume fluctuations. It is often necessary, and it is difficult to respond flexibly, and there is a case where long-term production stoppage is forced when equipment is introduced or modified.

  A flexible production system is a system that is suitable for producing as many models as needed in small quantities, for example, because of the need to respond to changing consumer needs and diversification in the fields of the automobile industry and the electrical industry. . An example of this system is a so-called cell production system. The cell production system is a highly self-contained system in which one worker performs a plurality of work processes at a work place called a predetermined cell to produce one product or a finished product for each of the plurality of processes. The cell production system and the cell production system using this system have the advantages that they can promote the multi-skilling of workers, can easily cope with changes in product specifications, and require less capital investment.

  By the way, in a cell production system, a work by an operator such as assembling a part to a work is replaced with a robot. That is, a cell production system is configured by a robot cell in which a robot is arranged in a cell as a worker instead of a human cell in which a person as an operator is arranged in the cell.

  In the cell production system using robot cells as described above, when one robot performs a plurality of types of work processes to produce a plurality of products in batches, the robot hands are exchanged according to the different types of work processes. It is necessary to prepare necessary works and parts automatically and appropriately. Therefore, an article assembling apparatus is known in which the order of work steps and the system configuration are devised to shorten the time required for such replacement and preparation (see, for example, Patent Document 1).

In addition, when the flexible production system is configured with a cell production system, a plurality of cells may be combined in addition to the configuration with a single cell. In the cell production system, the robot cell is usually one robot per cell, but the human cell is composed of a team of several people and works in one cell, in addition to the case of one worker per cell. Sometimes. A flexible production system incorporating such a cell production system can be flexibly adapted by changing the product model, increasing or decreasing the production amount, etc., compared to a conventional line production system.
JP-A-8-197343 (Patent No. 3528297)

  However, in a flexible production system to which the above-described cell production system is applied, it is required to deal with increase and decrease in production quantity more flexibly and in a shorter time. For example, when the production system is composed of a mixture of robot cells and human cells, in order to cope with the decrease in production volume, the human cells are arranged to reduce surplus workers without reducing the operation rate of the robot cells. If the system can be used for other work, the production cost can be reduced and the system can be made more flexible.

  The present invention solves the above-mentioned problems, and with a simple configuration, while maintaining productivity without lowering the operation rate of equipment, it can flexibly and easily respond to increase / decrease in production quantity than before. The purpose is to provide a flexible production system.

In order to achieve the above-mentioned object, the invention of claim 1 is directed to a conveying means that circulates and conveys an article to be assembled along a conveying path, and an assembling operation or a process for the article to be assembled that has been conveyed by the conveying means. In a flexible production system that includes a plurality of function cells set as work areas, and that accommodates an increase or decrease in production volume, assembly that is arranged in each function cell and assembles a part to the assembly A plurality of automatic machines having a known machine characteristic for performing work or processing work, and an assignment determining means for deciding how many automatic machines of which machine characteristic are assigned to each functional cell; The plurality of functional cells include a robot cell in which a robot performs a supply / removal operation of an article to be assembled and a part to / from the automatic machine, and a person who performs the supply / removal operation. And a human cell for the allocation determining means, when changing the production, by the number of persons is entered that is set assigned to each of the number and the human cells in the robot cell and human cells, these input information On the basis of the mechanical characteristics of each automatic machine, the assignment of the automatic machine to each functional cell is determined so that the working time of each functional cell is made uniform.

  According to a second aspect of the present invention, in the flexible production system according to the first aspect, the conveyance path is configured such that a start point and an end point are at the same position.

  According to a third aspect of the present invention, in the flexible production system according to the first or second aspect, the human cells are arranged so as to be concentrated in one place or to be continuous along the transport path. .

  According to the invention of claim 1, since the work time in each functional cell is equalized by the allocation of automatic machines to each functional cell, without reducing the operating rate of equipment and functional cells such as individual automatic machines, While maintaining productivity, it is possible to respond flexibly and easily to changes in production volume than before. In other words, the present invention enables work processes to be distributed to a plurality of functional cells so as to be able to flexibly respond to an increase / decrease in production volume. By predetermining the number of human cells and robot cells to be used, the number of people assigned to the human cell, and the number and type of each automatic machine (mechanical characteristics of each automatic machine) according to the increase or decrease in production volume The production system can be easily constructed and reconstructed by the allocation determining means, and the production quantity can be flexibly dealt with. Devices can be arranged and configured so that the cycle time of each functional cell is constant, and it is possible to cope with an increase or decrease in the number of production without reducing the operating rate of each functional cell.

  According to the invention of claim 2, by making the start point and the end point of the conveyance path the same position, the place where the workpiece, that is, the assembled product is put in, and the place where the finished product is picked up can be consolidated into one place, The working distance can be reduced and work efficiency can be increased. Similarly, when a part is transported using a transport path, similarly, the supply location of the part can be made the same as the place where the assembled product is placed, and the working efficiency can be improved.

  According to the invention of claim 3, since the human cells are arranged at one place so as to be concentrated or continuous along the conveyance path, it is easy to change work assignment in the human cells. In addition, it is possible to avoid problems such as disposing a plurality of workers at a distant place even though the work time is short, and it is possible to reduce the number of people and the number of people.

  Hereinafter, a flexible production system according to an embodiment of the present invention will be described with reference to the drawings.

(First embodiment)
FIG. 1 schematically shows an application example of the flexible production system according to the first embodiment, FIG. 2 shows another application example of the production system, and FIG. 3 shows the flexible production system shown in FIGS. The structure in is compared and shown. Hereinafter, the outline of the flexible production system 1 will be mainly shown in FIG. 1, and then detailed description will be given.

  As shown in FIG. 1, the flexible production system 1 includes a conveyor 3 that is a conveyance unit that includes a conveyance path 30 and circulates an assembly product, and an assembly product that is conveyed by the conveyor 3. A plurality of (four in this example) function cells FC set as areas for performing assembly work or machining work, and supply of parts to be assembled to the assembled product, processing of the assembled product, etc. Is a so-called cell production system production system including automatic machines A and B (to be described later) that perform the above and an assignment determination device 2 that selects and assigns each automatic machine A and B to each functional cell FC. . Furthermore, the flexible production system 1 is a flexible production system using a mixed cell (hybrid cell) including both the human cell MC and the robot cell RC1.

  This flexible production system 1 makes it possible to flexibly and easily respond to the increase or decrease in production quantity without reducing the operation rate of the functional cell FC. In addition, the automatic arrangement of the automatic machines A and B arranged in the functional cell FC is efficiently performed. On the contrary, the function of each functional cell FC is changed by changing the arrangement of the automatic machines A and B. As a result of such rearrangement, for example, FIG. 1 is configured to increase production, and FIG. 2 is configured to reduce production.

  The functional cell FC performs assembly work or processing work on the assembly product and robot cell RC1 etc. in which the robot R1 or the like set for each functional cell FC performs assembly work or processing work on the assembly product. It is composed of a person cell MC or the like performed by one or more persons. In the example shown in FIG. 1, the configuration includes three robot cells RC1, RC2, and RC3 in which robots R1, R2, and R3 are arranged, and one human cell MC in which three people m1, m2, and m3 are arranged. It is shown.

  As described above, the assignment determination device 2 inputs the number of human cells MC to which three persons are set and assigned as the number of persons per person cell MC and the number 3 of robot cells RC1 and the like. Based on the above, automatic machine assignment as shown in FIG. 1 is performed. That is, the assignment determination device 2 assigns the automatic machines A, B, etc. to each functional cell FC so that the working time of each functional cell FC is equalized.

  In this case, more generally, each automatic machine A, B, etc. is arranged in each functional cell FC and performs an assembling operation or a processing operation for assembling the parts to the assembled product. Have a known mechanical characteristic, and the plurality of functional cells FC are equipped with a robot cell RC1 etc. in which the robot R1 etc. performs the supply / removal work of the assembled parts and parts with respect to the automatic machines A, B, etc. The assignment determination device 2 includes the human cell MC etc. performed by m1 etc., and the number of robot cells RC1 etc. and each of the human cell MC etc. Based on the input information and the mechanical characteristics of each automatic machine A, B, etc., the assignment of the automatic machines A, B, etc. to each functional cell FC is determined so that the working time of each functional cell FC is equalized.

  As described above, the uniform work time means that there is no waiting time between the functional cells FC and each functional cell FC operates efficiently. That is, each device including an automatic machine is arranged and configured so that the cycle time of each functional cell FC is constant.

  In the example shown in FIG. 1, the assignment determination device 2 assigns the automatic machines A and B to the robot cell RC1, the automatic machine C to the robot cell RC2, the automatic machines D and E to the robot cell RC3, and the automatic machine to the human cell MC. F to L are assigned.

  Each automatic machine A, B, etc. is standardized, generalized and unitized, and can be exchanged between the robots R1, R2, R3, etc. Thus, the standardization and generalization of each automatic machine A, B, etc. has been made, so that the assignment determination device 2 can perform the above assignment.

  In addition, each automatic machine A, B, etc. has been standardized, generalized and unitized so that the automatic machine can be easily moved and installed not only between robot cells but also between human cells and robot cells. In addition, each automatic machine can be operated independently by unitization. Therefore, by designing the workpiece delivery unit so that it can be handled by either a person or a robot, a predetermined process can be completed simply by loading and unloading the workpiece with respect to the automatic machine.

  According to the flexible production system 1 of the present embodiment, the work time in each functional cell FC is equalized by the assignment of the automatic machines A to L to each functional cell FC. While maintaining the productivity without reducing the operation rate of each functional cell, it is possible to flexibly and easily cope with the increase or decrease of the production quantity as compared with the conventional case.

  That is, according to the present invention, work processes can be distributed to a plurality of functional cells so as to be able to flexibly respond to increase / decrease in production volume. The number of human cells MC and robot cells RC1, etc. to be used and the number and type of automatic machines assigned to each cell according to the increase / decrease in production volume (mechanical characteristics of automatic machines with known assembly and processing time required) ) By predetermining the number of persons in the human cell MC, it is possible to easily construct a production system by the assignment setting means, and it is possible to flexibly cope with an increase or decrease in production quantity.

  Next, the configuration of the flexible production system 1 shown in FIG. 1 and the state of production in the configuration will be described in more detail. The allocation determination device 2 described above can be configured by a set of processes and functions on a computer and an electric computer having a general configuration including a CPU, a memory, an external storage device, a display device, an input device, a communication device, and the like. . Further, the allocation determining device 2 uses the function to store, display and present system layout information, and to perform information communication with each device in the host system 10 and the functional cell FC. Can do.

  The layout of the equipment in the flexible production system 1 is that the human cell MC and the robot cells RC1, RC2, RC3 are arranged in series in this order, and the conveyor 3 is arranged in parallel with the arrangement of the robot cells. 3, the inlet 3a and the outlet 3b are arranged at the boundary between the human cell MC and the robot cell RC1. As the conveyor 3 for conveyance, for example, a circulation free flow conveyor can be suitably used.

  The above-mentioned circulation free flow conveyor is a conveyor in which the conveyance path of the free flow conveyor is connected in a ring shape. In addition, the free flow conveyor is formed, for example, such that a conveyance path is formed by a belt, and the belt constantly moves during operation, but the belt and a conveyed product thereon slip. Therefore, the belt and the transported object continue to slip by appropriately stopping the transported object at the position of each functional cell FC, so that operations such as processing, taking out, and movement of the transported object can be performed in this state.

  However, in the conventional belt conveyor that is not the above-described free flow conveyor, the belt and the conveyed product do not slip, so that it is necessary to stop the belt when working on the conveyed product. If the conveyor is not moving, the conveyed product does not flow to the subsequent process, so the conveyed item is caught and a new input cannot be performed. Therefore, in order to increase the conveyance efficiency, the charging cycle must be observed.

  In this regard, in the above-described free flow conveyor, the belt always moves and the conveyed product flows to the subsequent process, so that a new conveyed product can be input. That is, in the free flow conveyor, the conveyed product can be fixed at a portion where positioning is required, and the other conveyed items continue to flow, so that it is not necessary to observe the charging cycle.

  Next, each robot cell will be described. Robots R1, R2, and R3 are respectively disposed at substantially central portions of the robot cells RC1, RC2, and RC3. Further, around each robot R, for example, in the case of the robot cell RC1, unitized automatic machines A and B are arranged. The automatic machines A and B are, for example, automatic devices such as a component supply palletizer, an adjusting machine, and a screwing machine. The same applies to the other automatic machines C, D and E.

  In addition, for example, a horizontal articulated robot or a so-called SCARA robot (SCARA: Selective Compliance Assembly Robot Arm) can be suitably used as the above-described robot. The SCARA robot is a type of industrial robot that moves in the horizontal direction and is suitable for automatic assembly operations such as component insertion and screw tightening. A palletizer as an automatic machine is an apparatus for automatically loading an object on a pallet.

  Each robot R1 etc. communicates with each automatic machine A, B etc. in each cell, and these always operate in synchronization with each other. Each robot cell RC1, RC2, RC3 communicates production information, for example, start and completion information for each work process, etc. with the host system 10 via a communication device (not shown). This production information is used for promptly responding to product type switching and equipment troubles.

  Automatic machines G to L are arranged in the human cell MC. These automatic machines G to L are automatic machines for performing complex assembly work and inspection packing work. These automatic machines can include semi-automatic machines that are assisted by humans. Parts shelves and the like are arranged in the regions O, P, and Q in the human cell MC. The automatic machine L is a carry-out work dedicated machine for carrying out a finished product, and as shown by an arrow 3d, the finished product that has been assembled with parts is carried out from the automatic machine L.

  Further, as described above, the human cell MC is provided with the inlet 3a and the outlet 3b of the conveyer 3 that communicates with the robot cells RC1, RC2, and RC3. The conveying conveyor 3 is configured to circulate, and the conveying pallet 31 is circulated and conveyed on the conveying path 30.

  The article to be assembled, that is, the workpiece, is set on the transfer pallet 31, is input from the input port 3a of the human cell MC, and is transferred toward the robot cell RC1 by the transfer conveyor 3. Thereafter, the workpieces are assembled in the robot cells RC1, RC2, and RC3 and transferred by the transfer conveyor 3, and are finally taken out from the outlet 3b in the human cell MC.

  Persons m1, m2, and m3 perform operations that are complicated for robots R1, R2, and R3, such as connector connection and wiping operations. The robots R1, R2, and R3 mainly perform operations for loading and unloading workpieces into and from automatic machines. Examples of the operations of the robot R1 and the like and the automatic machines A and B include a simple operation such as assembly of a circuit board. Each process and its order are set so that such a simple operation can be performed.

  Hereinafter, an operation example of the flexible production system 1 will be described. First, in the human cell MC, a part x1 (work) and a part x2 (both not shown) are set on a transport pallet 31 that moves on the transport conveyor 3, and transport is started by the transport conveyor 3. The robot R1 of the robot cell RC1 takes out the part x1 from the transfer pallet 31 that has been transferred into the cell by the transfer conveyor 3, and sets it in the assembly station 4.

  Next, the robot R1 takes out the part x3 (not shown) from the automatic machine B and attaches the part x3 to the part x1 set in the assembly station 4. The part x3 is a part that has been loaded from the automatic machine A to the automatic machine B by the robot R1 in the previous cycle and has been adjusted by the automatic machine B. The automatic machine A takes out the part x3 from a parts shelf (not shown) and performs processing. The part x1 (work) after the assembly of the part x3 is handled (transferred) from the assembly station 4 to the transfer pallet 31 and is transferred to the robot cell RC2 by the transfer conveyor 3.

  The workpiece (part x1) transferred from the robot cell RC1 is set on the assembly station 5 from the transfer pallet 31 by the robot R2 of the robot cell RC2. The robot R2 takes out the part x2 from the transfer pallet 31 and attaches the part x2 to the workpiece on the assembly station 5. After the assembly of the part x2, the workpiece is put into the automatic machine C arranged in the robot cell RC2 by the robot R2. Next, the robot R2 takes out the workpiece that has completed the process in the previous cycle, and sets it on the pallet 31 for conveyance. The workpiece that has finished the process is transferred to the robot cell RC3 by the transfer conveyor 3.

  The workpiece transferred from the robot cell RC2 to the robot cell RC3 is handled by the robot R3 and is loaded from the transfer pallet 31 to the automatic machine D. The robot R3 finishes the process in the previous cycle, takes out the workpiece stored in the automatic machine E, and handles it to the transfer pallet 31.

  The carrying pallet 31 carried out from the robot cell RC3 is forwarded to the human cell MC by the carrying conveyor 3. The work returned to the human cell MC by the transport pallet 31 is a finished product by performing manual operations such as assembly of other parts x4 (not shown), appearance inspection, and packing. The finished product is unloaded from the automatic machine L.

  Next, the flexible production system 1 having the layout at the time of production reduction shown in FIG. 2 will be described. The flexible production system 1 having this layout has a layout corresponding to a reduction in production quantity without lowering the operation rate of the functional cell FC, in particular, the operation rate of the robot cells RC1, RC2, and RC3. The basic idea is to save people (decrease the number of people) by making the robot work more versatile by making the robot more versatile. In general, a multi-skilled worker in a person is a worker who can perform a plurality of duties by one person with respect to a single-skilled person who has only one function.

  Therefore, in the flexible production system 1 of this embodiment, automatic machines A, B, etc. are utilized in order to make each robot R1, R2, R3 versatile. That is, by changing the layout of the automatic machines A, B, etc., the number of the automatic machines A, B, etc. assigned to the robots R1, R2, R3 is increased to achieve multi-functionality.

  For example, the automatic machines arranged for the robot R1 in the robot cell RC1 are automatic machines H to L instead of the automatic machines A and B (FIG. 1) at the time of mass production. The automatic machines H to L are automatic machines that were originally arranged in the human cell MC. The number of automatic machines for the robot R1 is two at the time of mass production, but is increased to five at the time of production reduction.

  Further, the automatic machines arranged for the robot R2 in the robot cell RC2 are automatic machines A and B instead of the automatic machine C (FIG. 1) at the time of mass production. The automatic machines A and B are automatic machines originally arranged in the robot cell RC1, and the number of automatic machines is increased from one to two.

  Further, the automatic machines arranged for the robot R3 in the robot cell RC3 are changed to the automatic machines C, D, E instead of the automatic machines D, E (FIG. 1) at the time of mass production. One unit has increased. In addition, an assembly station 6 is newly provided in the robot cell RC3.

  Further, since the automatic machine L is arranged in the robot cell RC1, the finished product is carried out from the robot cell RC1. For this reason, the person m1 in the person cell MC re-injects the finished product (not shown) into the conveyor 3 as indicated by the arrow 3c. The robot R1 inputs the re-entered finished product into the automatic machine L and carries out the finished product.

  FIG. 3 shows a comparison of the configuration of each functional cell FC in the flexible production system 1 during mass production and production reduction (FIGS. 1 and 2 respectively). This figure is also a comparative diagram of the number of steps in each functional cell FC. In the case of the example of this embodiment, in the process table 11 at the time of mass production, the number of processes for the human cell MC is larger than the number of processes for the robot cells RC1, RC2, and RC3. The number of processes for the cell MC is smaller than the number of processes for the robot cells RC1, RC2, RC3.

  In the configuration of the flexible production system 1 described above, the number of human cells MC is reduced from three at the time of mass production to one at the time of production reduction, and labor saving (reduced number of people) is achieved. This is also shown by the comparison diagram in FIG. More specifically, the cycle time of each functional cell FC is extended by changing the arrangement of the automatic machine. As a result, the process burden of the robot cells RC1, RC2, RC3 is increased, the process burden ratio of the human cell MC is decreased, and labor saving (decrease in number) is performed.

  Thus, according to the flexible production system 1 of the present embodiment, by changing the process burden ratio, it is possible to equalize the cycle time of each functional cell FC and easily cope with the increase or decrease in the number of production. . For example, if the cycle time for mass production is 10 seconds and the cycle is 15 seconds for production reduction, the number of production will be reduced by 1/3, but the operator will maintain the operating rate of equipment such as automatic machines and robots. The number can be reduced by 2/3 from 3 to 1.

  Moreover, the feature point is further demonstrated about the flexible production system 1 in this embodiment. That is, in the flexible production system 1 shown in FIG. 1, the human cell MC is arranged at one place, and the parts and workpiece input / output sections are integrated. For this reason, conveyance of a component and a workpiece | work can be performed easily.

  In addition, the conveyor 3 (free flow conveyor) is arranged so that the start point and the end point are at the same position, and the person cell MC on which a person works is provided at the start point and the end point, as described above. Human cell MC is arranged in one place. Thereby, a plurality of processes existing in one person cell MC can be shared by a plurality of workers.

  In addition, as described above, the parts and workpiece supply parts are consolidated, so it is possible to prevent an increase in the points for supplying parts and finished products from the marshaller. Thus, waste due to logistics waste and the movement of marshallers can be reduced, thereby enabling efficient supply and conveyance of parts. Also, the flexible production system 1 shown in FIG. 2 has the same effects as described above.

(Second Embodiment)
FIG. 4 schematically shows an application example of the flexible production system according to the second embodiment. The application example of the flexible production system 1 according to this embodiment reduces production by reducing the number of robot cells in the application example of the flexible production system 1 shown in FIG. 1 in the first embodiment from three to one. An example of handling is shown.

  The automatic cells A and B of the robot cell RC1 in FIG. 1 are additionally assigned to the human cell MC in FIG. 4, and only one robot cell RC1 in FIG. 4 is replaced with the automatic devices A and B in the case of FIG. Automatic machines C, D, and E are assigned. In this way, by assigning an automatic machine to each function cell so that the work time of each function cell is made uniform with respect to the human cell MC and the robot cell RC1, each robot increases the process burden. Production reduction measures are performed without reducing the operating rate of the cell RC1. The robot cells RC2 and RC3 removed in FIG. 4 are used in another flexible production system 1.

(Third embodiment)
FIG. 5 shows a flow of system setting processing in the flexible manufacturing system according to the third embodiment, and FIG. 6 shows another example of the system setting processing flow. This embodiment shows a process for realizing a system configuration in which an optimal device arrangement is made when the production amount is changed. As a method of the processing, there are a case of performing based on the input number of workers or the number of robot cells (FIG. 5) and a case of performing based on the input number of production (FIG. 6). In this embodiment, reference is made to FIGS. 1, 2, and 4 as reference configurations.

  In the case of the processing flow of FIG. 5, first, a production plan is read from the host system 10 (for example, see FIG. 1) into the allocation determination device 2 of the flexible production system 1 (# 1). Next, the number of human cells MC in which the number of persons per human cell MC is set and the number of robot cells RC1 and the like are input to the assignment determination device 2 (# 2). These inputs are performed by the host system 10 or directly by an operator who performs production management.

  Next, the allocation determining device 2 determines the function cell FC, the automatic machines A and B, and the necessary equipment (conveyor for transfer) from a plurality of layout information set and stored in advance according to the number of persons and the number of function cells. 3 or an assembly station) is selected (# 3). In the example of the processing flow of FIG. 5, for example, two types of production layouts La and Lb corresponding to FIGS. 2 and 4 at the time of production cut-off are stored, and the allocation determination device 2 sets one of them as an optimal layout. Select and display (# 4, # 5). For example, if the worker has one human cell and three robot cells, the layout shown in FIG. 2 is used. If the worker has one human cell and one robot cell, the robot shown in FIG. A layout is selected. Such layouts are not limited to two types, and a plurality of possible production layouts are prepared, stored, and displayed.

  The worker who performs production management and the worker, according to the displayed layout, the arrangement of each device including the automatic machine in the human cell MC and the robot cells RC1, RC2, RC3, and in some cases, the number of the functional cells FC, The actual devices and devices are changed (# 6). Each device, the robot R1, and the like are connected to each other via a signal line, and can communicate with the assignment determination device 2.

  As described above, after changing the actual device arrangement, the number of functional cells, and the like, the allocation determining device 2 of the flexible production system 1 recognizes the device configuration in each functional cell FC by communication, and determines the arrangement of each device and the above-described configuration. Consistency with the selected and displayed layout is confirmed (# 7). If the layout is not properly arranged (No in # 7), a message to that effect is displayed to prompt the worker to correct the equipment arrangement.

  The assignment determination device 2 operates each functional cell FC, an automatic machine in each cell, etc., when the assignment and arrangement of the device match with those presented by the system and become normal (Yes in # 7). The program is downloaded from the host system 10 to each device (# 8), and the production layout change is completed in a state where each device is operable.

  Next, the processing flow shown in FIG. 6 will be described. This processing flow is changed from the processing flow shown in FIG. 5 described above to the input (# 2) of the number of human cells MC and the number of robot cells RC1, etc. in which the number of persons per human cell MC is set, and the number of productions Is the same as the processing flow shown in FIG. The production number is input by the host system 10 or directly by an operator who performs production management.

  In this processing flow, since the number of human cells MC, robot cells RC1, etc. is determined by the number of productions required for the system, the production amount is input instead of the number of human cells MC, robot cells RC1, etc. The assignment determination device 2 determines the number of human cells MC, robot cells RC1, etc. based on the production volume, and selects and assigns automatic machines so that the work time in each functional cell FC is equalized. It is.

  However, in the case of the system setting process flow as described above, since the production layout cannot be uniquely determined only by the input production plan (# 1) and the number of productions (# 20), the assignment determination device 2 is set in advance. A plurality of layouts are presented in order, and automatic machine assignment and device placement are finally determined according to the judgment of an operator who performs production management.

  In any of the system setting processing flows of FIG. 5 and FIG. 6 described above, a large number of combination data such as the number of people and the number of functional cells is prepared in advance according to production conditions such as the number of productions, cycle time, and tact time. Thus, a more preferable production system can be formed easily and flexibly. In this case, as described above, standardization and generalization of automatic machines are important.

(Fourth embodiment)
FIG. 7A schematically shows an application example of the flexible production system according to the fourth embodiment, and FIG. 7B shows a comparative example with respect to (a). In the present embodiment, the flexible production system 1 is configured such that the conveyance path 30 of the conveyance conveyor 3 is configured such that the start point and the end point are at the same position, and the human cells MC are concentrated in one place. The effect of will be described.

  In these drawings, robot cells C1 to C5 and human cells in which people m1 to m4 are arranged (a human cell is different from a robot cell and forms a human cell with people close to each other) are outlined. The process flow (corresponding to the conveyance path 30) is indicated by an arrow.

  In general, some production processes are highly effective when performed manually. On the other hand, due to the structure of the product, there is a part where the order of each process cannot be changed (the part in the broken line in the figure). Then, as in the comparative example shown in FIG. 7B, if people m3 and m4 (by human cell) are arranged in the assembly process order, one person is also added to the portion where only 0.5 man-hours are required. The name must be placed and it is uneconomical. Therefore, without changing the non-replaceable part of the process order, and changing the arrangement in the replaceable part and setting as shown in FIG. 7A, in the comparative example, there were four people, In FIG. 7A, it is possible to perform work by three people, and a labor saving effect is obtained.

  As described above, it is possible to avoid problems such as disposing a plurality of workers at distant locations even though the work time is short, and the number of workers can be saved. Further, by concentrating the human cells in one place, it is easy to change work assignments in the human cells.

  Also, as shown in FIG. 7 (a), FIG. 1, FIG. 2, and FIG. 4, by setting the start point and end point of the conveyance path 30 to the same position, the parts supply / removal part, the workpiece, that is, the assembled product input The mouth 3a and the finished product outlet 3b can be integrated into one place, and the working distance can be increased by reducing the moving distance for loading and unloading.

(Fifth embodiment)
FIG. 8A schematically shows the effect of the flexible production system according to the fifth embodiment, FIG. 8B shows the effect of FIG. 8A by a Gantt chart, and FIGS. FIG. 8A and FIG. 8B show comparative examples. In the present embodiment, an effect of a flexible production system using a mixed cell (hybrid cell) including both a human cell and a robot cell will be described.

  In the case of a production system that is not hybrid, for example, a production system composed of only three human cells arranged by two persons, as shown in FIGS. Only 33% can be reduced.

  However, for example, in a flexible production system using a hybrid cell composed of three human cells and three robot cells arranged one by one, as shown in FIGS. 8A and 8B, 33% When reducing production, it is possible to reduce the number of people by 66% and save labor.

  This indicates that, when the production is reduced, the robot takes over the work of the person, so that unlike the conventional single person cell, the hybrid cell achieves a large labor saving (decrease in manpower). That is, this means that the work time ratio before the production cut is (person) :( robot) = 1: 1, and the work time ratio at the time of 33% production cut is (person) :( robot) = 1: 3. It is understood from that.

  The present invention is not limited to the above-described configuration, and various modifications can be made. For example, the parts to be put into the robot cell do not necessarily need to be thrown only from the slot 3a, and screw parts can be supplied from a parts box provided in each automatic machine. In addition, the allocation of automatic machines to each robot cell or human cell is performed in consideration of the capability difference without uniformizing the capabilities of each robot or human. In addition, the configurations of the above-described embodiments can be combined with each other within a consistent range, and embodiments of such configurations that can be combined are naturally included in the present invention even if they are not specified.

The top view which shows typically the example of application of the flexible production system which concerns on the 1st Embodiment of this invention. The top view which shows typically the other application example of a production system same as the above. The comparison figure of the structure in the flexible production system shown in FIG. 1, FIG. The top view which shows typically the example of application of the flexible production system which concerns on 2nd Embodiment. The flowchart of the system setting process in the flexible production system which concerns on 3rd Embodiment. The flowchart which shows the other example of the system setting process in a production system same as the above. (A) is a top view which shows typically the application example of the flexible production system which concerns on 4th Embodiment, (b) is a top view which shows the comparative example with respect to the application example of (a). (A) is a schematic diagram for demonstrating the effect of the flexible production system which concerns on 5th Embodiment, (b) is a Gantt chart which compares and shows the effect of (a). (A) is a schematic diagram which shows the effect of the comparative example with respect to Fig.7 (a), (b) is a Gantt chart which compares and shows the effect of (a).

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Flexible production system 2 Allocation determination apparatus 3 Conveyor 30 Conveyance path AL Automatic machine FC Function cell R Robot m, m1-m3 person MC person cell RC1, RC2, RC3 Robot cell

Claims (3)

A transport unit that circulates and transports the assembly product along the transport path, and a plurality of functional cells that are set as areas for performing assembly or processing operations on the assembly product transported by the transport unit. In a flexible production system that responds to changes in production volume
A plurality of automatic machines having mechanical properties with known time required for the assembly operation or processing operation for assembling a part to the assembly object arranged in each functional cell;
Allocation determination means for determining how many automatic machines of which mechanical characteristics are allocated to each functional cell,
The plurality of functional cells include a robot cell in which a robot performs a supply / removal operation of an assembly product and a part to / from the automatic machine, and a human cell in which a person performs the supply / removal operation,
The allocation determining means inputs the number of robot cells and human cells and the number of persons assigned to the human cells when changing the production amount, and the input information and the mechanical characteristics of each automatic machine. Based on the above, a flexible production system, wherein the allocation of the automatic machine to each functional cell is determined so that the working time of each functional cell is equalized.   The flexible production system according to claim 1, wherein the conveyance path is configured such that a start point and an end point are at the same position.   3. The flexible production system according to claim 1, wherein the human cells are arranged so as to be concentrated at one place or to be continuous along the conveyance path.

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