1756-EN3TR一個(gè)是從涂裝工序向整車組裝工序轉(zhuǎn)移的時(shí)候。在涂裝工序中,涂裝作業(yè)不是完全遵守整車順序生產(chǎn)計(jì)劃的順序。比如說,當(dāng)前方車輛為雙色,后續(xù)車輛為單色時(shí),單色車輛會(huì)先行完成涂裝,趕超前方車輛。趕超的車輛如果直接進(jìn)入下面的整車組裝工序,部件和模塊的供應(yīng)就無法同步。
為此,日產(chǎn)車體九州在涂裝工序與整車組裝工序之間,設(shè)置了叫作“PBS(Paint Up Body Storage)”的臨時(shí)等候場(chǎng)所(圖5)。PBS可以容納40輛汽車,最多可以調(diào)整1個(gè)小時(shí)的作業(yè)時(shí)差。
1756-EN3TR當(dāng)涂裝工序中發(fā)生趕超時(shí),趕超的車輛要在PBS中等候。等被超車輛進(jìn)入PBS后,再回到原本的隊(duì)列中,進(jìn)入下面的整車組裝工序。
整車順序生產(chǎn)計(jì)劃被打亂的另一個(gè)地方是在整車組裝工序中(圖6)。整車組裝工序從入口到出口,由1條生產(chǎn)線連接,但是因?yàn)檐囕v結(jié)構(gòu)的差異,途中存在一些先分岔后匯合的工序(圖7)。那就是安裝發(fā)動(dòng)機(jī)和變速箱等驅(qū)動(dòng)部件的工序。這道工序分為在車體上安裝驅(qū)動(dòng)部件的“單體”和在框架上安裝的“框架”。安裝驅(qū)動(dòng)部件后,會(huì)按照原本的車輛排列,恢復(fù)成1條生產(chǎn)線。
這兩個(gè)地方都不經(jīng)由人工。完全由生產(chǎn)線控制服務(wù)器自動(dòng)進(jìn)行判斷。
機(jī)器人唱主角的制造現(xiàn)場(chǎng)
1756-EN3TR車體焊接工序雖然大量使用機(jī)器人,但頂板制造等部分工序,還保留著手工作業(yè)(圖8)。不過,這些作業(yè)并不復(fù)雜,可以很容易替換成機(jī)器人。
1756-EN3TR
1756-ENBT
1756-ESMCAP
1756-ESMNRM
1756-ESMNSE
1756-HIST1G3277
1756-HIST2G3278
1756-HSC
1756-HYD02
1756-IA16
1756-IA16I
1756-IA32
1756-IA8D
1756-IB16
1756-IB16D
1756-IB16I
1756-IB16ISOE
1756-IB32
1756-IC16
1756-IF16
1756-IF16H
1756-IF4FXOF2F
1756-IF6CIS
1756-IF6I
1756-IF8
1756-IF8H
1756-IG16
1756-IH16I
1756-IH16ISOE
3HAA0001-FT Reduction Gear RV-30AT-57
3HAA0001-GN Wrist
3HAA0001-GY Interm. Wheel Unit
3HAA0001-HA Gear Unit
3HAA0001-HJ Reduction Gear RV-30AT-81
3HAA0001-JA Cable Axis 5
3HAA0001-JC Cable Axis 6
3HAA0001-M Gear unit
3HAA0001-SK CABLE
3HAA0001-SY LIFT DEVICE FOR FORKLIFT
3HAA0001-UA ACCESSORIES FOR TCP-ADJ.
3HAA0001-UL RADIALFAN
3HAA0001-XH MOTOR AX.1
3HAA0001-XJ MOTOR AX.2-3
3HAA0001-XK MOTOR AX.6
3HAA0001-XR CALIBRATION EQUIPMENT
3HAA0001-YG CABL.UPPER.NO CUST-CONN.
3HAA0001-YH Cabl.upper.Front c-conn.
3HAA0001-YM Lower cabel
3HAA0001-YN LOWER CABLE,FRONT C-CONN.
3HAA0001-YP LOWER CABLE SHELF,C-CONN.
3HAA0001-YR Cablage axis 5
3HAA0001-YS Cablage axis 5
3HAA0001-YT Cable axis 6
3HAA0001-YU Cable axis 6