JP2973745B2 - Quality control system for goods production process - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a quality control system for ensuring production quality in the production process of articles such as automobiles, and more particularly, to the identification of work equipment which has caused a defect and the repair and repair of the equipment. The present invention relates to a quality control system that facilitates appropriate modification of work setting contents.

[0002]

2. Description of the Related Art Generally, the production of automobiles as an example of articles generally includes a body assembly process for assembling a vehicle body, a painting process for painting the vehicle body, and interior / exterior parts, drive system parts, and steering system parts on the painted body. The vehicle is manufactured through a vehicle assembling process for assembling the vehicle and the like, and the produced vehicle is inspected for production quality in a final inspection process, and is shipped when it passes the quality inspection. In addition, these contents,
The entire book is introduced in the entire volume of Automotive Engineering Volume 19 (published by Sankaido Co., Ltd. on April 20, 1980).

In the meantime, the management of production quality in each of the above-described vehicle assembly processes such as body assembly, painting, and vehicle assembly has conventionally been carried out in each of those processes based on predetermined specifications based on prescribed specifications instructed in accordance with a production plan. After performing the work in sequence according to the contents, inspecting the car in the middle of production that performed the work, further inspecting the car produced in the final inspection process as described above, and if any defect is found in those inspections, While reworking a defective car, based on the equipment operation record and production plan, etc., the work condition of the work that caused the malfunction in the process that caused the malfunction, that is, the work equipment performed the work according to what setting contents Follow-up surveys are conducted to determine whether the work has been performed and whether the work has been performed according to the settings. There, the review of the settings by performing, to prevent the occurrence of subsequent problems, has been carried out in such a way that if there is a problem in work settings of the equipment.

[0004]

However, the working conditions of the working equipment include changes in the surrounding environment, wear of the operating parts,
While it varies from moment to moment due to various factors, such as the use of a plurality of facilities according to the production plan, and actually varies from one car to the other, the above-described conventional production quality management method uses facility operation records and Since work conditions are estimated retroactively from rough data such as a production plan, the work conditions at the time of actual production do not directly correspond to the quality inspection results, and there has been no means for making them correspond. For this reason, in the conventional management method described above, it is difficult to accurately grasp the working conditions during the actual work of the vehicle having the problem, and the work equipment that has caused the problem is identified, and its repair and work setting are performed. There was a problem that it took a lot of time and effort to make appropriate corrections to the content.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide a quality control system which advantageously solves the above-mentioned problems, and a quality control system for an article production process according to the present invention is shown in FIG. As shown in the concept, work data output means 1 provided in work equipment in the process of producing an article, reads out work conditions each time work is performed on the work equipment, and outputs as work data together with the work date and time; Inspection data output means provided in at least one of a step of producing an article and a subsequent inspection step, for outputting, as inspection data, an inspection result of at least one of each article in production and each article produced; Transport means 3 for sequentially recording the output work data and inspection data and transporting the data together with the article.
And provided in work equipment during the process of producing the article,
Time-varying data output means 4 for reading out the time-varying changes in the working conditions of the work equipment and outputting as time-varying data.
And quality control for reading out the work data and inspection data recorded in the data transfer means, combining the read out work data and the output aging data, and outputting the work conditions and the inspection results at the time of production of each article in association with each other. Data output means 5,
It is equipped with.

[0006]

In such a system, during the production of an article, the data transfer means 3 which moves along with each article is output by the work data output means 1 during the production process of the article. Work data indicating work conditions such as the work equipment that performed the work, the work setting contents, the actual work contents at the time of the work, and the date and time when the work was performed,
Inspection data output by the inspection data output means 2 in the above-mentioned production process or a subsequent inspection process, for example, the inspection data indicating the inspection result of each article in the course of production, such as the assembly dimensions of the main body, the coating quality, the assembling accuracy of various parts, etc. After recording and transporting, the quality control data output means 5 associates the work data recorded by the data transport means 3 associated with each article with the inspection data, and outputs the time-varying data output means 4. Based on the time-dependent change data and the work time indicated by the work data, the conditions at the time of working on the work under the work conditions of the work equipment that change over time also correspond to the inspection data, so that the And output the work conditions at the time of production and the inspection results in association with each other.

Therefore, according to this system, the data recording means 3 and the time-varying data output means 4 share the data and supply the data to the quality control data output means 5 according to, for example, the importance and amount of the data. Therefore, work data at the time of actual work and inspection data indicating the result of the work can be supplied in a form that can easily and accurately take correspondence between them, and quality control is performed based on the data. Since the data output means 5 outputs the work conditions at the time of production of each article and the inspection result in association with each other, if there is a defect in the middle of production or in the produced article, the work which caused the defect was created. It is possible to easily specify the equipment, repair the equipment, and appropriately correct the work setting contents in a short time.

Further, according to the system of the present invention, by accumulating data on a large number of articles produced and statistically processing the data, the time-dependent change in working conditions and the time-dependent change in the production quality of articles can be obtained. Can be accurately grasped, so that when setting new work equipment or changing the contents of work setting for changing the type of article, it is possible to complete the work conditions in a shorter time.

[0009]

Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 2 shows an automobile production management system of a new factory including one embodiment in which the quality management system of the article production process of the present invention is applied to the production of automobiles as articles.
FIG. 2 is a configuration diagram together with the system of the existing factory, and includes a gateway (G / W) 12 and a local area network (LA) in an overall management computer denoted by reference numeral 11 in the figure.
N) 13 is connected to a factory host computer 14 for determining the production order, controlling the cost of each part, and the like. The factory host computer 14 and the gateway 12 are connected via a packet communication network 15 to a head office computer 16, Technology Research Laboratory Computer 17 and other factory host computers
An office management file server (F / S) 19 and some terminal devices 20 are connected to the LAN 13, and the gateway 12 is further connected to the component manufacturer for providing information to component manufacturers. A computer of a component maker (not shown) is also connected.

The overall management computer 11 also includes a production management F / S 24, several terminal devices 25, and an existing press factory management computer via a main LAN 23 having a management LAN 21 and a production information LAN 22. 26, an existing body factory management computer 27, an existing painting factory management computer 28, an existing assembly factory management computer 29, and an inter-process operation computer 30 are connected to each other. Reference numeral 29 denotes a conventional production management system together with the overall management computer 11 for operating the existing factory, and the inter-process operation computer 30 is a computer for controlling equipment such as a conveyor connecting the processes. Several controllers 31 are connected.

On the other hand, a new production management system including the quality control system of this embodiment, which controls the production of the above-mentioned new factory, which comprises a new body factory, a new painting factory, and a new assembly factory, is used together with the existing system. The overall management computer 11 has a hierarchical structure with the highest level, and the next level after the highest level is a process management in which the new factory is largely divided into three processes of body assembly, painting, and vehicle assembly. The process management level includes a body assembly process management computer 32 connected to the overall management computer 11 via the trunk LAN 21 for managing the body assembly process in the new body factory, and a painting system in the new paint factory. A painting process management computer 33 that manages the process, and a vehicle that manages the vehicle assembly process and the final inspection process (final process) in the new assembly plant An assembly process management computer 34 is provided.

At a level lower than the process management level, the inside of each process is divided into several cells according to functions, and the cells are managed for each cell, and the inside of each cell is managed for each station. The station management level and the device management level for managing the inside of each station for each work facility sequentially form hierarchies, and FIGS. 3 to 5 show the configuration of these hierarchies for each factory. The process management computers 32 to 34 are connected to the main LAN 21.
Is also connected to a quality control F / S 35 to be described later.

FIG. 3 shows a system for managing the body assembly process in the new body factory. The body assembly process management computer 32 at the process management level includes an online computer 32a which normally operates and a computer for the same. Backup computer that runs when 32a fails
32b are connected in parallel, and two databases (D / B) 36 comprising hard disk drives are provided so as to be shared by them, and a D / B 37 for storing quality history is further provided.

The cell management level lower than the process management level at the new body factory is connected to the process management computer 32 via an in-process LAN 40 having a management system LAN 38 and a production instruction system LAN 39. A plurality of cell controllers 41 for cell management, a plurality of terminal devices 42 for data input / output, and an ID card
Cell controller 44 for managing data exchanged with 43
And multiple cell controllers for production instructions to sub-processes
A terminal server (T / S) 46, which is a kind of LAN terminal device, for outputting a management system instruction to an operator is provided. A plurality of cell controllers 41 for cell management are provided here. Engine compartment (E / C) set for main process, floor main (F / MAIN) assembly, rear floor (RR / FLOOR) assembly, body side left / right (B / S-LH, RH) set, body main (B / MAIN) Assembling and assembling metal (doors, engine hood, etc.) in functional cells, and controlling the metal sub-process in functional cells such as door assembling, engine hood assembling, and the like for each of those cells.

Further, a station management level, which is lower than the cell management level in the new vehicle body factory and manages the inside of the cell for each station, is connected via the LAN 47 to the plurality of cell controllers 41 for the assembly process, respectively. A programmable logic controller (PLC) 48 for each station comprising a computer, and a cell controller 44 for managing the ID card data via a LAN 49
A plurality of ID controllers 50 for controlling the transfer of information to the ID card 43 connected to the ID card 43 and a plurality of PLCs 52 for each sub-process station connected to the plurality of sub-process production instruction cell controllers 45 via the LAN 51, respectively.
And a result display panel 53 and a printer 54 connected to the T / S 46, respectively. The lower device management level of the station management level includes a PL for each station.
There is a PLC 55 connected to C48 and 52, respectively, for controlling the operation of work equipment such as a welding robot and a part positioning device.

By the way, the ID controller here
Reference numeral 50 denotes each cell including a wireless transmission / reception circuit, various memories, and a control computer, including the first cell for setting the engine compartment and the last cell for checking the assembly accuracy of the body main in the main assembly process. And selectively transmitting a predetermined data reception start signal and a predetermined data transmission start signal, and an ID controller for the transmission.
The transmission of work data and inspection data, which will be described later, of the equipment provided with 50 and the reception of signals from the ID card 43 are performed.

The ID card 43 includes a wireless transmission / reception circuit, a read-only memory (ROM), a readable / writable memory (RAM), and a control computer operating based on a program written in the ROM. It is configured in a pack (for example, see the one proposed by the present applicant in Japanese Patent Application Laid-Open No. 61-108080).
In the cell for setting the engine compartment in the main assembly process, after the identification number of the automobile to be produced is given as data from the ID controller 50, the cell is mounted in the engine compartment for constituting the automobile with the identification number. After that, the vehicle moves along with each car under production until it is removed before a painting process described later.

When the ID card 43 approaches the ID controller 50 at each cell in the main assembly process, the ID controller 50 transmits a data reception start signal. The data transmitted by the ID controller 50 is received and stored in the RAM, and the ID controller 50 transmits a data transmission start signal. Transmit the data stored in.

FIG. 4 shows a system for managing the painting process in the new painting factory. The painting process management computer 33 at the process management level includes an online computer 33a which also operates normally and its computer.
Backup computer that operates when 33a fails
b are connected in parallel, and a management LAN
A quality history storage D composed of a hard disk drive via an in-process LAN 58 having a LAN 56 and a production instruction system LAN 57
/ B59 and an input / output terminal device 60 are connected.
The cell controller connected to the process control computer 33 via the in-process LAN 58 has a cell control level lower than the process control level in the new painting factory.
Cell controller 61 for managing ID card data having the same function as 44, and cell controller 62 for quality control
A T / S 63 for inputting / outputting data, a T / S 64 for outputting an instruction of a management system to an operator, and a printer 65 for printing out quality data and production management data. .

Further, a node 66 is connected to the process control computer 33 via another in-process LAN 67 by a node 66 at a station control level, which is lower than the cell control level in the new painting factory and controls the inside of the cell for each station. A plurality of PLCs 68 for controlling each of the steps of undercoating, intermediate coating, and overcoating, and the ID connected to the cell controller 61 for managing the ID card data via a LAN 69.
A plurality of ID controllers 70 having the same configuration as the controller 50 for controlling the transfer of information to and from an ID card 43 and an ID card 79 described later, and quality data input / output connected to the quality control cell controller 62 via a LAN 71 Terminal 72 for general data input / output connected to the T / S 63 for data input / output, and the T / S 64 for output of management system instruction to the worker, respectively. A display work instruction panel 74 and a result display panel 75 are provided.

Further, the lower level of the station management level includes a coating robot, an electrodeposition coating apparatus, and the like, which are connected to the PLC 68 for each of the above-described undercoating, intermediate coating, and topcoating processes via the LANs 76 and 77, respectively. There is a PLC 78 for controlling the operation of the work equipment of the above, and an ID card 79 having the same structure as the above-mentioned ID card 43 and having a heat and dustproof liquid tight specification so as to be suitable for use in the painting process. 79 is mounted on the vehicle body at a position where it does not hinder the painting work before the assembled vehicle body enters the painting process, and the ID card 43 used in the previous vehicle body assembly process While being removed from the compartment, various data stored in the ID card 43 is stored in the ID card 79 via the ID controller 70. It is.

FIG. 5 shows a system for managing the vehicle assembling process and the final inspection process in the new assembly plant. Here, the vehicle assembling process management computer 34 at the process management level is an on-line computer which is also operated normally. A computer 34a and a backup computer 34b operating in the event of a failure of the computer 34a are connected in parallel, and are provided with two databases (D / B) 80 comprising hard disk drives so as to be shared by them. Further, an engineering workstation (EWS) 81 for assembling quality control having a terminal device, various external storage devices, and a printer, and an EW for failure cause analysis (not shown)
S is provided.

The cell management level lower than the cell management level in the new assembly factory is connected to the process management computer 34 via the in-process LAN 83 having input / output terminal devices 82 at various points in the process. A cell controller 84 for managing a painted body line (PBL) and a main line, a cell controller 85 for managing a subline, and a final inspection step (final step) connected to the EWS 81 for inspection and the EWS for failure cause analysis, respectively. ), A cell controller 87 for work instructions and quality control on a manned line on the first floor of the factory where the final inspection process is performed, and a cell controller 87 for the above-mentioned PBL, main line and sub-line on the second floor of the factory. A cell controller 88 for work instructions and quality control on manned lines is provided,
These cell controllers 84 to 88 are also input / output terminal devices.
89 to 93 respectively.

Here, the PBL transfers the painted vehicle body to a guideway type train, removes the ID card 79 from the vehicle body, and transfers the data recorded on the ID card 79 to a computer in the train. The main line is a trim for installing wiring and piping, electrical components and hydraulic components, instrument panels and lining, etc. Under floor line (U
/ F), a unit mount line (U / M) for mounting a unit that integrates the engine and the transmission, and a chassis line for mounting final assembly parts such as glass, batteries, and seats. It has a related assembly line, door related assembly line and tire related assembly line.

In the final inspection step, the produced automobiles, which have been assembled and become self-propelled, can be taken off from the trains and the data recorded by the computer in the trains can be transferred. Off-line for re-installing the ID card 43 on the produced car, CS line for inspecting the specifications and construction of the produced car, tester line for performing alignment test, headlamp test, brake test, shower test, etc., after the test To conduct watertightness inspections and quality inspections of the above vehicles
It has a K line, a rust prevention line for performing rust prevention treatment on vehicles that have passed the inspection results, and a repair zone for repairing vehicles where defects have been found. It is installed on the CS line in the final inspection process.

Further, at the station management level lower than the cell management level in the new assembly factory, PBL, trim, and PBL connected to the line management cell controllers 84 to 86 and connected to each other via the LAN 94, respectively. It has the same configuration as the ID controller 50, which is connected to a PLC 95 for each line such as U / F, a production result display panel 96 for display to an operator, and a cell controller 84 for main line management. A plurality of ID controllers 97 for controlling the transfer of information to the train, and a delivery date display panel 9 connected to a cell controller 86 for managing the final inspection process.
8. A tester automatic determination recording device 99 comprising a computer, an OK processing device 100 and a final process ID management device 101, and a quality control cell controller 87 on the first floor.
Specification indicating device 103 connected to the system via an interface (I / F) 102, a quality check processing device 104 which is a terminal device having a printer, a tightening assurance device for important security components
105, etc., and a parts specification indicating device 103, a quality check processing device 104, and a tightening assurance device for important security components connected to the quality control cell controller 87 on the second floor via the I / F 102.
105 and a VID label issuing device 106.

Here, the VID label issuing device 106
Received from the train at the last position of the above chassis line,
The data of the identification number of the car produced by the train is converted into a bar code, a VID label on which the bar code is printed is issued, and the VID label is printed on an instrument panel of each produced car. The master device in the OK processing device 100 is mounted on the tester line, and the operator reads out the bar code of the VID label which is taken out from each vehicle to be inspected by the tester line and put into the device. To each tester, and the slave device in the OK processing device 100
The operator takes out the bar code of the VID label which is taken out of the car which passed the inspection result in the OK line and put into the apparatus by reading the VID label, and sends the identification number of the passed car to the cell controller 86 for the final inspection process management. Inform.

The device management level lower than the station management level includes a PLC 95 for each line.
A plurality of PLCs 107 for controlling the operation of an automation master and a component supply conveyor (C / V), controlling the interval between trains, and the like, respectively,
A PLC (not shown) connected to the LC 107 for controlling work equipment such as a robot for automatically mounting interior parts such as seats,
An ID card connected to the final process ID management device 101 and having the same configuration as the ID controller 50
A plurality of ID controllers 108 for controlling the transfer of information to and from the ID 43 are provided.

In this production management system, when a production plan determined by the factory host computer 14 by exchanging information with the head office computer 16 is given from the factory host computer 14 to the overall management computer 11, The overall management computer 11 gives production plans to the production management system of the existing factory and the production management system of the new factory according to the type of vehicle to be produced.
The production control computers 26 to 29 and the inter-process operation computer 30 of each factory perform the production of automobiles in the usual processes of press, body, painting, and assembly in a predetermined production order based on the given production plan. And its production quality control is
Inspections are performed in two stages: quality inspection in each process and inspection in the final inspection process.If a defect is found, we will review not only the vehicle concerned but also the work equipment that caused it. ing. However, in this existing factory, it is not possible to grasp the actual working conditions for each car, and the working conditions at the time of the work will be estimated from equipment operation records and production plans, etc. It is not always easy to identify the work equipment that caused the failure based on the inspection results, repair the equipment, and appropriately correct the work settings.

On the other hand, in the new factory, the process management computers 32 to 34 of each factory to which the production plan has been given from the overall management computer 11 transmit the IDs based on the production plan.
Using the cards 43 and 79 and the computer in the train to control the location of each vehicle, each cell controller is required to perform the production of the vehicle in each of the vehicle body, painting, and assembly processes in a predetermined production order. The production quality control is carried out in two stages: quality inspection in each process and inspection in the final inspection process. If a defect is found, not only rework of the vehicle, but also The quality control system is reviewing the work equipment that has caused this.

Here, the quality control in the new factory will be specifically described. First, in the vehicle body assembling process, a welding robot which performs temporary assembly of the vehicle body and additional spot welding for each vehicle body at each station. An identification number, an energizing time and a current value for each spot when the welding robot performs spot welding on the vehicle body, and a vehicle body panel automatic combining a plurality of positioning robots with each body panel constituting the vehicle body to be temporarily assembled. The operation conditions of the positioning jigs at the time of positioning by the positioning device, as well as the data of the date and time when each work was performed, as well as data on what day and what time, are used as work data, and the operation of those robots and devices is performed. P to control
The work data output by the LC 55 is supplied to the process control computer 32 by the cell controller 41 connected to the PLC 55, and the work control computer 32
D is supplied to the ID controller 50 of the station via the D management cell controller 44,
Is recorded on the ID card 43 mounted on the vehicle body on which the work was performed.

In this vehicle body assembling process, at the last vehicle body assembling accuracy measuring station, a vehicle body assembling accuracy automatic measuring device combining a plurality of laser type distance measuring devices for each vehicle body performs in-line measurement of the assembly accuracy. The result is output by the PLC 55 that controls the operation of the device, and the measurement data is supplied to the process management computer 32 by the cell controller 41 connected to the PLC 55, and the measurement data is sent to the process management computer 32 for ID management. The ID is supplied to the ID controller 50 of the vehicle body assembly accuracy measuring station via the cell controller 44, and the measurement data transmitted by the ID controller 50 is transmitted to the ID mounted on the vehicle body that has performed the measurement.
The card 43 records.

Further, in the above-mentioned vehicle body assembling process, in addition to the results of the visual inspection of the assembled vehicle body, the results of the welding quality inspection performed by sampling, and the like, the time when the welding tip was replaced as the history data of the working conditions that change with time of each facility. The operator supplies data such as the time when periodic inspections of equipment and facilities were performed from the in-process terminal device 42 to the process management computer 32, and the process management computer 32
32 supplies the data to the quality history storage D / B 37 for recording there.

Then, in the undercoating step of the next coating step,
As shown in the right half of FIG. 6, a voltage is applied to the vehicle body 110 and the electrode 111 in the electrodeposition tank 109 to apply the electrodeposition paint 112 to the vehicle body 110. The concentration and liquid temperature, and the data of electrodeposition coating voltage and current,
The PLC 78 for controlling the operation of the coating apparatus 113 outputs the history data of the working conditions that change over time of the equipment, and the process management computer 33 supplies the history data to the quality history storage D / B 59, where To record. Here, as shown in the left half of FIG. 6, the worker who measured the thickness of the undercoating film for each vehicle body at the last film thickness measuring station 114 of the undercoating line reads the film thickness data. Supply from the terminal device 72 to the process management computer 33 via the quality control cell controller 62, and the process management computer 33
The film thickness data is supplied to the ID controller 70 of the film thickness measuring station 114 via the ID management cell controller 61, and the film thickness data transmitted by the ID controller 70 is read by the ID mounted on the vehicle body 110. card
43 records.

In the intermediate coating step and the top coating step in the above-mentioned coating step, as shown in the right half of FIG.
The coating robot 118 having a bell-shaped spray gun in a painting booth 117 having a paint sprayer 5 and an exhaust device 116 has a plurality of coating booths 117 for coating the vehicle body 110. The electrostatic coating voltage and the number of revolutions of the bell-type spray gun were, for each vehicle body, as well as data that the date and time when the coating work was performed was over what day and at what time. The output from the PLC 78 for controlling the operation is output to the process control computer 33.
Transmits the work data via the ID management cell controller 61 to the ID controllers provided in the respective processes.
70, and transmits the work data transmitted by the ID controller 70 to the I / O mounted on the painted body 110.
The D card 79 records. Also here, each painting booth 11
The data of the humidity and temperature of the inside and the temperature and viscosity of the paint are used as the history data of the operating conditions of the equipment that change with time, and the PL that controls the operation of the equipment in the coating booth 117 is used.
The process control computer 33 supplies the history data to the quality history storage D / B 59, where it is recorded by the process management computer 33.

In the overcoating line, FIG.
As shown in the left half of the above, the sharpness automatic measuring device 120 at the last sharpness measuring station 119 of the overcoating line, the sharpness data of the overcoating film measured by a plurality of points for each vehicle body, The PLC 78 for controlling the operation of the automatic sharpness measuring device 120 outputs the data, and the process control computer 33 transmits the sharpness data to the ID controller 70 of the sharpness measuring station 119 via the ID management cell controller 61.
, And transmits the sharpness data transmitted by the ID controller 70 to the I / O mounted on the painted body 110.
The D card 79 records.

Further, in the next vehicle assembling process, as shown in FIG. 8, as an on-line process, the operation of the automatic machine 123 on the vehicle body 110 on the train 121 and the main line 122, the door and engine relationships (not shown), In the operation of the automatic machine 123 in the tire related sub-line, for example, if there is a problem such as insufficient bolt tightening torque or insufficient gasoline supply amount, if the problem is corrected, such defect information is
The PLC 95 for each line outputs the defect information, and the main or sub line management cell controllers 84 and 85 connected to the PLC 95 supply the defect information to the process management computer 34,
The process management computer 34 stores the defect information in LA.
Send to assembly quality engineering workstation (EWS) 81 via N22.

In this case, as the online processing, the process management computer 34 operates through the cell controllers 87 and 88,
The parts specification data of the automobile under production is sent to the parts specification indicating device 103 on the first floor and the second floor, and the order sheets are issued to the devices 103, and the worker sends the order sheet to each body 110 based on the order sheets. The parts are assembled, and similarly, the process management computer 34 sends the data of the inspection contents of the vehicle body 110 of each car being produced and each produced car 125 to the quality check processing device 104 on the first and second floors,
For example, a check sheet as shown in FIG. 9 is issued to the devices 104, and an operator performs an inspection based on the check sheet. If it is corrected, the defect information and the defect information are input to the process management computer 34 from the terminal device 82 in the process, and the process management computer 34
34 transmits the above inspection data to the assembly quality EWS via the LAN 22.
Send to 81.

Further, here, as an on-line process, the tester automatic judgment recording device 99 outputs, when the test result of the produced automobile 125 has a defect in the tester line of the final inspection step 124, the defect information, and outputs the final information. The management cell controller 86 sends the defect information to the process management computer 34, and the process management computer 34
Sends the defect information to the assembly quality EWS81.

The assembling quality EWS81 creates a final reconfirmation list based on the defect information of the automatic machine 123 and the defect information of assembling the important security parts.
The list is issued from the printer provided on the CS line in the final inspection step 124, and the CS line operator reconfirms the quality of the produced automobile 125 that came to the line based on the final reconfirmation list. The above assembly quality E
The WS 81 supplies the defect information of the automatic machine 123, the defect information of the important security parts, and the defect information on the tester line to the quality control file server (F / S) 35 via the LAN 21, Record it there.

In the vehicle assembly process, as shown in FIG. 10, as an off-line process, the worker in the repair zone in the final inspection process 124 sends the repair result of the defective vehicle from the terminal device 82 to the process management computer 34. Then, the process management computer 34 supplies the result of the modification to the quality control F / S 35 via the LAN 21 and records it there. Further, here, a production menu listing production management items such as a direct rate, which is a ratio of the number of vehicles that passed the inspection to the number of vehicles put into the production process, and a delayed vehicle information, from the terminal device 82 of the production management office. The process management computer 34
And a quality menu listing quality control items such as inspection results and automatic machine fault information.
/ S35, and the terminal 82 of the quality control office
, The quality analysis personnel inputs the quality data analysis result and other inspection data to the quality control F / S 35.

In this case, as an off-line process, the process management computer 34 creates a production menu in which data such as the above-mentioned crossing rate and delayed car information is entered based on various data supplied thereto, and the production menu Is output to the terminal device 82 of the rest area of each process, and the quality control F / S 35 writes data such as the above-mentioned inspection results and automatic machine trouble information based on various data supplied thereto. , And the quality menu is output to the terminal device 82 of the rest area of each process.

In addition, in the quality control system of this embodiment, the process control computer 34
The data of the identification number of 3, the work conditions for each car body 110 or each door, each engine / transmission unit, etc. attached to it, and the work date and time when the work was performed, Along with the defect information, the information is supplied to a train control PLC 107 via a line management cell controller 89 and a line-based PLC 95, and the PLC 107 transmits data including the defect information to a communication line provided along a guideway. Then, the work is sent to a computer in the train 121 on which the body 110 that has performed the work or the body 110 on which the work or the like has been mounted is mounted and recorded there.

Also, here, a tester automatic judgment recording device
The defect information of the test result of the vehicle 125 on the tester line output by the 99 is also sent by the process management computer 34 to the ID controller 108 via the final process management cell controller 86 and the final process ID management device 101, and the ID controller 108 Is transmitted to the ID card 43 mounted on the automobile 125 on which the test is performed.

Further, here, the ID controller 108 in the last step of the final inspection step 124 mounts the ID card 43 recorded on the ID card 43 removed from each automobile 125 that has passed the inspection. Had been a car 125
Of the final process ID management apparatus 101 and the final process management cell controller 86
Via the LAN 21 to the quality control F / S 35 via the LAN 21. The process management computer 34 sends data indicating the actual working conditions of each vehicle 125 to the quality control F / S 35 via the LAN 21.

The quality control F / S 35 in the system of this embodiment, which has received the various data, receives the data, for example, every day on the day when the factory starts operating, and at the time when the automobile production work on that day ends, for example, as shown in FIG. As shown in FIG. 12, a list showing actual work conditions, work times, and inspection results in each production process recorded in the ID card of each car produced on that day and a booth in the painting process are shown in FIG. As shown in FIG. 13, a graph showing changes in working conditions that change over time of each facility, for example, as shown in FIG. 13 for a vehicle assembly process,
The list of inspection results and information on assembly failure of parts input by the operator from the terminal device 82, and an action card for instructing inspection and correction of the equipment having a defect, in particular, are stored in the terminal device 82 of the quality control office. Based on the printed list and the action card, the quality control personnel at the quality control office print out and inspect the equipment that had a defect and the equipment that is likely to have a defect, and based on the results, Repairs and work settings will be corrected accordingly.

That is, in the vehicle body assembling step, the position and shape of the positioning jig are judged based on, for example, the measurement result of the vehicle body assembling accuracy and the position data of the positioning jig when the vehicle body is assembled, and the change is made. And the accuracy of the body panel alone can be reviewed.For example, based on the results of welding quality inspection and welding current data and welding tip replacement data when welding is performed, welding time setting and welding can be performed. The setting of the chip replacement period can be reviewed. For the coating process, review the coating conditions based on, for example, the passing time of the process of the body where the film thickness and sharpness of the coating film were defective, the history data of the painting booth at that time, and the operating conditions of the coating robot. It can be carried out. For the vehicle assembling process, for example, the window glass assembling operation time and the identification number of the robot that performed the operation, and the amount of adhesive discharged from the window glass at the time of the operation, for example, when the water tightness test result of the tester was defective. From the data, the window glass assembling procedure can be reviewed and the setting of the adhesive discharge amount can be reviewed.

As shown in FIG. 10, the above-mentioned quality control office is provided with the above-mentioned engineering workstation (EWS) 126 for analyzing the cause of a defect.
Since the process management computer 34 supplies the above data to the EWS 126 for analyzing the cause of the problem via the LAN 21, even if the list and the action card are examined, the equipment having the problem can be identified and the cause of the problem can be identified. If the identification is difficult, the failure cause is statistically analyzed using a failure cause analysis program (so-called AI) provided in the EWS 126 for failure cause analysis, and the equipment having the failure is identified and the cause of the failure is identified. Can also be specified.

Therefore, according to the quality control system of this embodiment, the PLCs 55, 78, 107 for controlling the work equipment in each step constitute the work data output means 1, and the PLCs 55, 78 for controlling the inspection equipment in each step. , 107 constitute the inspection data output means 2, and the ID cards 43, 79 as the data recording means 3, the computer in the train 121, and the time-varying data output means 4 according to the importance and amount of the data. The quality history storage D / Bs 37 and 59 and the assembly quality EWS81 share the data and supply the data to the quality control F / S 35 as the quality control data output means 5. Inspection data indicating the results of the inspection can be supplied in such a manner that correspondence between them can be easily and accurately taken, and the quality control F /
Since S35 outputs the working conditions and inspection results in the production of each vehicle in association with each other, if there is a problem in the middle of production or in the produced vehicle, the work equipment that caused the problem is identified. The repair of the equipment and the appropriate correction of the work setting contents can be easily performed in a short time.

Further, according to the system of this embodiment, the EWS 126 for analyzing the cause of failure accumulates data on a large number of automobiles produced and statistically processes the data. In addition to accurately grasping the relationship between production quality and changes over time,
As shown in Fig. 14, it is also possible to perform aggregation by defect category, so that when setting up new work equipment or changing the work setting contents for changing the model, etc., it is possible to complete the work conditions in a shorter time. Can be.

Although the present invention has been described with reference to the illustrated examples, the present invention is not limited to the above-described example. For example, the system of the present invention may be used in a vehicle assembly process, a painting process, a vehicle It can be used independently or separately in the assembling step or other steps such as the assembling step of an automobile body panel, or can be used alone in that step alone. Further, the system of the present invention is not limited to automobiles, but can be applied to other articles such as electronic parts.

[0052]

As described above, according to the quality control system for the article production process of the present invention, the work data at the time of the actual work and the inspection data indicating the result of the work can be easily and accurately correlated with each other. Can be supplied in any possible form,
Also, if there is a defect in the production or during the production, it is easy to identify the work equipment that caused the defect, repair the equipment, and appropriately correct the work settings in a short time. Can be.

Further, according to the system of the present invention, by accumulating data on a large number of produced articles and statistically processing the data, the time-dependent change in working conditions and the time-dependent change in the production quality of the articles can be obtained. Can be accurately grasped, so that when setting new work equipment or changing the contents of work setting for changing the type of article, it is possible to complete the work conditions in a shorter time.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram showing a configuration of a quality management system in an article production process of the present invention.

FIG. 2 is a configuration diagram showing an outline of an automobile production management system of a new factory together with a system of an existing factory, including an embodiment in which the quality management system of the article production process of the present invention is applied to automobile production.

FIG. 3 is a configuration diagram showing a management system for a vehicle body assembling process of a new vehicle body factory in the vehicle production management system.

FIG. 4 is a configuration diagram showing a management system for a painting process in a new painting factory, of the automobile production management system.

FIG. 5 is a configuration diagram showing a management system of a vehicle assembly process and a final inspection process of a new assembly plant in the above-mentioned automobile production management system.

FIG. 6 is an explanatory view showing an undercoating step in the above-mentioned coating step.

FIG. 7 is an explanatory view showing an overcoating step in the above coating step.

FIG. 8 is an explanatory diagram showing an online management system in the management system of the vehicle assembly process and the final inspection process.

FIG. 9 is an explanatory diagram showing an example of a check sheet output in the vehicle assembly process and the final inspection process.

FIG. 10 is an explanatory diagram showing an off-line management system in the management system of the vehicle assembly process and the final inspection process.

FIG. 11 is an explanatory diagram showing an example of a list of work conditions, work times, and inspection results in each production process of each vehicle output by a quality control file server in the system of the embodiment as production quality control data. It is.

FIG. 12 is an explanatory diagram showing an example of a graph showing a transition of a work condition that changes with time of each facility output from a quality management file server in the system of the embodiment as production quality management data.

FIG. 13 is an explanatory diagram showing an example of a list of inspection results and assembly defect information output by a quality management file server in the system of the embodiment as production quality management data.

FIG. 14 is an explanatory diagram showing an example of a total graph for each defect classification, which is output from a defect cause analysis engineering workstation in the system of the embodiment as production quality management data.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Work data output means 2 Inspection data output means 3 Data recording means 4 Temporal change data output means 5 Quality control data output means 35 Quality control file server (F / S) 37, 59 Quality history storage database (D / B) 43, 79 ID card 55, 78, 107 Programmable controller (PLC) 81 Assembly quality engineering workstation (E
WS) 110 Body 121 Train 126 Engineering workstation for failure analysis (EWS)

Continued on the front page (72) Inventor Hiroshi Tamashima 2 Takaracho, Kanagawa-ku, Yokohama, Kanagawa Prefecture, Nissan Motor Co., Ltd. (72) Inventor Hiroyuki Takano 2 Takaracho, Kanagawa-ku, Yokohama, Kanagawa Prefecture, Nissan Motor Co., Ltd. (72 Inventor Masaaki Inoue 2 Takara-cho, Kanagawa-ku, Yokohama-shi, Kanagawa Nissan Motor Co., Ltd. (56) References JP-A-1-257549 (JP, A) JP-A-2-131847 (JP, A) 2-284853 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) B23Q 37/00-41/08

Claims (1)

(57) [Claims] 1. A work data output means (1) provided in a work facility in a process of producing an article, for reading out work conditions each time the work facility is operated, and outputting the work conditions together with the work date and time as work data; An inspection data output means (2) which is provided in at least one of a step of producing an article and a subsequent inspection step, and outputs inspection results of at least one of each article during production and each produced article as inspection data; A data transfer means (3) which moves along with the article, sequentially records the output work data and inspection data, and transports the work data and the inspection data together with the article; and Time-varying data output means (4) for reading out the time-varying changes in the working conditions of the work equipment and outputting as time-varying data
And quality control for reading out the work data and the inspection data recorded in the data transfer means, combining the read out with the output time-varying data, and correlating the work conditions at the time of production of each article with the inspection results and outputting the results. A quality control system for an article production process, comprising: a data output means (5).