Package making – Methods – Wrapping contents including cover forming
Reexamination Certificate
2002-08-01
2004-08-03
Rada, Rinaldi I. (Department: 3721)
Package making
Methods
Wrapping contents including cover forming
C053S441000, C053S447000, C053S428000
Reexamination Certificate
active
06769230
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a favorable collective and centralized inventory storing method for sheet metal parts such as sheet metal repair parts for automobiles which are required to store for a long time.
2. Description of the Prior Art
When the semi-finished products etc. available for daily production are stocked, there is not caused a big problem in storage and inventory management because the number of days for storage is several days at the longest. One example of such an inventory management for the semi-finished products for a short period of time is known and disclosed in Japanese Unexamined Utility Model Publication No. HEI 6-43750 (1994). However, in the case where repair parts have a predetermined deadline for storing and they are comparatively large sheet metal parts, the situation is quite different from the above.
Shown in the upper section A of
FIG. 1
is a conventional storing method of a sheet metal parts for repairing of this kind such as a rear floor panel corresponding to a rear outside sheet of automobiles. Each rear floor panel which is a finished product provided with predetermined processes such as press working and coating is packed to provide a style of packing for sale
1
which is then stored in a storage-rack
2
one by one, then in a warehouse. Each size of height (Y), width (X) and thickness (H) in this packing style for the finished product for sale
1
is comparatively large. Inventory adjustment of the sheet metal parts for repairing are made based on the predetermined demand forecasting and even though production of the automobile has been ended, the sheet metal parts for repairing are required to store and supply for a predetermined period of time after that.
The upper section of
FIG. 2
shows each process of production to storage of the sheet metal parts in the conventional example. First, an original sheet
3
is prepared (process (
1
)) and then drawn to a certain shape to provide a drawn part
4
(process (
2
)). The drawn part is further processed to have a concavo-convex shape thereon and trimmed to provide a trimmed product
5
(process (
3
)). The trimmed product
5
is bent or the predetermined area thereof is pierced to provide a press-finished product
6
(process (
4
)). Press working is completed by this process (
4
). Then, small parts etc. are integrally welded to the press-finished product
6
to provide a sub-component product
7
(process (
5
)). The_sub-component product
7
is then coated to obtain a finished product
8
(process (
6
)) which is then packed one by one to provide a packing style for the finished product
1
(process (
7
)). The sheet metal parts are manufactured in a small lot according to the situation of inventory and thus, the inventory is adjusted.
In the conventional example, since the sheet metal parts are stored in a packing style for the finished product
1
, much space for storage is required and storage costs increase. In particular, since the sheet metal parts such as the outside sheet for automobiles have an inclination to become larger, the storage costs increase accordingly. Since the sheet metal parts are continuously manufactured many times in a small lot according to the stock condition, production costs also increase.
Further, to supply the sheet metal parts for a long time by such an intermittent production, it is necessary to store the metal die for the whole period time. As a result, the storage cost for the metal die, the rust-preventive expenses, maintenance costs and the like generate and these are also primary factors for increase in costs for inventory storage. Still further, if the sheet metal parts are large, the production site is naturally limited to a large factory which can own a large metal die for producing such a large part. It is therefore difficult for a comparatively small factory to take such a mobile action as to produce the parts in a small lot.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an efficient inventory storing method for such sheet metal parts for repairing.
To solve the above-mentioned problems, a collective and centralized inventory storing method of sheet metal repair parts according to the present invention is provided, in which the sheet metal repair parts are made from a sheet shaped member through each process of drawing, press working, welding and coating, characterized in that when the forecasted number of demand is lower than a predetermined set value, a plurality of sheet metal parts are collectively enclosed by a rust-preventive sheet in a semi-finished product condition at least before coating to store them as one package, and a metal die is abandoned.
In this case, the predetermined set value in the forecasted number of demand can be the value in the case where packing volume of the semi-finished products to be collectively stored coincides with the cubic volume of the metal die, and in the case where an amount for storing the packed parts coincides with an amount for storing the metal die.
Further, the semi-finished product to be stocked can be either the trimmed product in the middle of press working or the sub-component product obtained by integrally forming other parts with the press-finished product. Structure of the sub-component product can be either the product obtained by integrally welding other parts to the press-finished product or the product obtained by integrally combining other parts with the press-finished product or the semi-finished product (hereinafter referred to as “combination”) so that they can be stored together.
According to the present invention, when the forecasted number of demand reaches a predetermined set value, the sheet metal parts for repairing are collectively manufactured as the semi-finished product, and a plurality of finished products are packed and stored as one unit. In this manner, space for storage can be remarkably reduced. Further, since the metal die is abandoned at the same time, it is no more necessary to store the metal die for a long time and as a result, increase in costs can be avoided.
The collectively stored semi-finished products can be additionally processed at a later stage according to a demand and supplied as the finished product in the necessary quantity. Since the semi-finished product is not provided with coating, necessary color coating can be applied thereto according to a demand and it is possible to flexibly cope with the difference in the number of demand every color. It is also possible to keep the coating of the semi-finished product free from any damage. The inventory of which the storage deadline has expired can be abandoned in the semi-finished product condition. Accordingly, the cost resulting from the abandonment can be saved because processes to the finished product have been omitted.
If the predetermined set value in the forecasted number of demand is the value in the case where the packing volume of the semi-finished product to be collectively stored coincides with the cubic volume of the metal die, even though the semi-finished products are stored for a predetermined long period of time after that, it is possible to make the storage space minimal by abandoning the metal die because the storage space for the abandoned metal die can be appropriated for the semi-finished product. It is also possible to make the inventory storage of the sheet metal parts for repairing advantageous for a long period of time.
Further, the semi-finished product to be stocked can be either the trimmed product in the middle of press working process, the press-finished product or the sub-component product obtained by welding other parts to the press-finished product. In the case of the trimmed product, it is possible to make the storage space minimal because the cubic volume per piece is minimal. In the case of the press-finished product, the cubic volume becomes larger than that of the trimmed product, but since the process which requires a large press machine is completed, the process
Handa Akira
Noshiro Masato
Yoshikawa Kenji
Rada Rinaldi I.
Weeks Gloria R
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